Ibero Group reduces quality defects by 98% in 4 months

Industry: Automotive

Client Overview
Ibero Group, a leading manufacturer of heavy vehicle automotive parts in Brazil, has embarked on a digital transformation initiative named Ibero 5.0. As part of this strategy, they sought to enhance efficiency, minimize quality issues, and improve visibility across their manufacturing operation as a key enabler of the programme. With rising expectations for precision and customer satisfaction, Ibero Group partnered with TilliT to deliver Digital Operations as a connected frontline worker platform and manufacturing execution system.

TilliT's CTO Rafael Amaral and Ibero staff inspecting existing operations at assembly stages.

The Challenge

Before adopting TilliT, Ibero Group faced challenges in the areas of quality, visibility of production status and process management characterised by:

• High defect rates, detected in the final assembly and inspection area.
• Inconsistent tracking of operational activities, asset performance, and order statuses.
• Limited visibility into critical operational data, hindering real-time decision-making.

The absence of centralized and automated operations and quality management system resulted in inefficiencies, higher rework costs, and a longer time to resolution for defects.

The Solution

TilliT Digital Operations was implemented as a comprehensive solution to address these challenges. The platform introduced:

• Digital Work Order execution: removal of paper job sheets and specs with a shift to kiosk-based terminal and mobile application access for all work order information and instructions.
• Digital Quality Management: Real-time tracking and recording of all quality-critical activities.
• End-to-End Visibility: Instant access to operational data, asset performance metrics, and order progress.
• Preventive Maintenance Tracking: Automated reminders for equipment maintenance to minimize downtime and defects.
• Process Setup Validation: Enhanced quality assurance through digital validation.

Results

Since implementing TilliT in August 2024, Grupo Ibero has experienced a remarkable transformation in its operational performance:

• Quality Improvement:
  • Defect rates started dropping the first day TilliT was enabled and has continued, culminating in only a single defect reported after only 3.5 months in operation.
  • Rejected units in final inspection have been reduced by over 97% from around 10% to less than 2%.
  • Cumulative reduction in quality issues has significantly cut rework costs, increased on time delivery and improved customer satisfaction.

• Enhanced Visibility:
• • Real-time monitoring of operational activities has empowered managers to make data-driven decisions.
  • Asset performance and order statuses are now fully transparent, enabling better planning and resource allocation.
• Operational Excellence:
  • With reliable digital tracking, auditability has increased, fostering trust among stakeholders.
  • Preventive maintenance schedules have reduced unexpected downtime.
    
    

Team Perspective

Guilherme Martinez, Digital Projects Engineer at Ibero Group, shares his insights on the impact of TilliT:

"The implementation of TilliT has been a game-changer for us. The reduction in defects and rework has not only saved costs but also significantly boosted team morale. Having real-time visibility into our operations allows us to proactively address issues before they escalate. We are only scratching the surface when it comes to Ibero5.0 and we are proud to see how far we’ve come in just a few months. We are excited to continue leveraging this technology for even greater results across other parts of the operation."

Rafael Amaral, Chief Technology Officer at TilliT, states:

"Ibero is the perfect example of a company with the optimal approach to digital transformation. They start with a strategy that sets the tone for the organisation and includes digital operations a key enabler. To see how quickly the results came was remarkable and is testament to their team and the technology which is very easy to implement, scale and maintain. We look forward to supporting Ibero Group as they work towards Ibero 5.0 over the coming months."

Conclusion

Ibero Groups success story highlights the power of low-code digital transformation in manufacturing operations. By adopting TilliT and implementing it themselves with a small team of experts, the company has achieved remarkable quality improvements, operational transparency, and cost savings. Starting with a specific high-value use case, proving the TilliT rapid onboarding model works and scaling from that baseline is a key benefit of the TilliT approach providing a future proof platform that adapts as our customers grow. This case study underscores how embracing innovative cloud and SaaS technologies can lead to sustainable business transformation and operational excellence.

For more information on how TilliT can revolutionize your operations, contact us today!