Synergy 2000 SPC Delivers Results
Halla Achieves 80% Scrap Reduction
Halla, a producer of automotive air conditioning components, implemented Synergy 2000 SPC software to enhance its processes and minimize errors. This resulted in an 80% reduction in scrap rate, a decrease in Parts Per Million (PPM) from 50 to 10, a reduction in data entry errors, and the ability to meet Automotive Industry Action Group (AIAG) reporting requirements. The software helped them transition from a manual, paper-based system to an online SPC system and provided clarity on process control.
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With Synergy 2000 SPC Software, Halla Reduced Scrap Rate by 80%
Executive Summary
Halla Climate Control Canada is a leader in the production of underbody refrigerant and coolant lines, accumulators/receiver driers, blower units, and clutch components used in automotive air conditioning compressors. Every system they manufacture is custom-designed for each specific model of vehicle, producing a unique set of dimensions, configurations, and performance requirements related to quality.
The Challenge
Reduce Parts Per Million (PPM)
The Solution
The Results
Reduced PPM from 50 to 10
Reduced data entry errors
Comply with AIAG reporting requirements
80% reduction in scrap rate
The Details
Halla Climate Control Canada is a leader in the production of underbody refrigerant and coolant lines, accumulators/receiver driers, blower units, and clutch components used in automotive air conditioning compressors. Every system they manufacture is custom-designed for each specific model of vehicle, producing a unique set of dimensions, configurations, and performance requirements related to quality.” We specialize in automotive air conditioning components,” said Dan Corrigan, Operational Excellence Manager.
With a total of more than 500 employees in 2 plants, many of whom have to enter data 3 times a shift, Halla cannot afford data entry errors. With Synergy, it doesn’t have to. “The system is very user-friendly. The team members can go up and call up their databank for a part. With the click of a button, they can input the data. No mistakes are made on entry because the system prompts the team member right on the spot,” said Corrigan.
With reporting requirements from AIAG (Automotive Industry Action Group) as well as those of his customers, Corrigan needs Statistical Process Control (SPC) software that allows for easy data extraction. “With the Synergy SPC software, we have the data we need to meet these reporting requirements,” said Corrigan.
Prior to Synergy, Halla was using a manual process for SPC reporting. Their biggest success has been in the end-forming area, where they create the couplings that will eventually be crimped to the hose. It was an area where they previously had constant issues every shift: non-conforming products, scrap, and rework. About three months after implementing the Synergy 2000 software, they noticed a drop in the scrap rate. They improved by at least 80%, and rework also decreased.
With the help of Synergy, Halla has been able to transition from a paper-based system to an online SPC system, saving time in data transcription and highlighting problems on the shop floor.
“Using the data from Synergy and a lot of hard work, we have been able to reduce our PPM (Parts Per Million) from 50 to 10,” said Corrigan. “Synergy highlights for me what I need to do next. It shows me where the process is out of control, so we can address it.”
Corrigan said they currently have an initiative to drive for Six Sigma 1 PPM and that Synergy will be instrumental in helping them get there.
“With Synergy, we have the data we need to meet our AIAG (Automotive Industry Action Group) and customer reporting requirements.” – Dan Corrigan Operational Excellence Manager for Halla Climate Control Canada
Streamlined, user-friendly system
Improved efficiency across shifts
Minimized risk of compliance issues or rework
Clarity and improved decision-making
About Zontec
Trusted since 1983, Zontec is a seasoned provider of statistical process control (SPC) software to companies across every industrial sector. We are highly respected for our singular commitment to the innovation and aggressive product development of SynergySPC quality software with in-house creation, testing, documentation, and technical support.
SynergySPC software helps manufacturers understand the process stability and capability of their operation with real-time data for early detection of special causes, continuous quality improvement, and ongoing return on investment.
Our latest update to Synergy2000 now has Smart SPC Intelligence, which reviews the charts produced by the software and analyzes them, providing a clear understanding of what is happening in manufacturing processes and how to improve them.
Contact us today to schedule a no-obligation call and learn more about whether Synergy is right for you.
Learn more about Synergy 2000
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