1. Customer Brief Card

Tianjin Woory Electronics Co., Ltd. was established on August 1, 2003, mainly engaged in the manufacture of electronic components, sales of electronic components and electromechanical assembly equipment, industrial design services, and research and development of automotive parts.

Its parent company is Woory Industrial Co., Ltd. in South Korea, founded on February 27, 1989. "Woory Automotive / ILEX Co., Ltd. / Tianjin Woory Electronics Co., Ltd. (China) / Dalian Woory Electronics Co., Ltd. (China) / Woory Industrial Thailand (Thailand) / Woory Automotive India (India) / Woory Mexico (Mexico) / Woory Slovakia (Slovakia) / Woory America (USA) / Woory Vietnam (Vietnam)" are all subsidiaries. Since its establishment in 1989, WOORY has been leading the development of automotive air conditioning components and automotive electronic components starting with the production of fuel senders as automotive components to achieve comfortable and safe driving. In addition, Woory Industrial has developed core components applicable to environmentally friendly vehicles, such as new energy vehicles and hydrogen fuel cell vehicles, to enhance its capability of providing new products for global customers.

• Staff Size: 100+

• Production Value: 300 million+ RMB

• Industry Status: The parent company has ranked first in the global market share with a market share of 34% for automotive actuators and 33% for high voltage PTC heaters. Additionally, high voltage PTC heaters for electric vehicles are closely following, ranking third with a 20% market share.

• Application Industry: Automotive parts manufacturing

• Main Markets: Overseas, Domestic

• Main Clients: Mercedes-Benz, Hyundai, Silver Wheel, SAIC, Tesla, ZhiJi, Xiaomi, etc.

• Production Process: Assembly, Testing

• Global Distribution: China, South Korea, USA, Mexico, Vietnam, Slovakia, India, etc.

• Main Products:

  1. HVAC Actuator

  Usage: Automotive (internal combustion engine, electric vehicle) indoor air conditioning actuators.

  Function: Controls the functions of air outlet/air conditioning/temperature control/airflow direction by being installed on HVAC (Heating, Ventilation, and Air Conditioning).

  2. High Voltage PTC Heater

  Usage: High voltage electric heater used for heating the interior of environmentally friendly vehicles (EV, FCEV).

  Function: Utilizes the characteristics of PTC (Positive Temperature Coefficient) components to perform the function of an electric heater for heating the interior of environmentally friendly vehicles - directly heating the air by being installed in HVAC - compact packaging of heater parts and control units - realizing the protection function of high voltage equipment.

  3. Cooling Liquid Heater

  Usage: Battery cooling liquid that maintains battery temperature to improve fuel efficiency of environmentally friendly vehicles (EV, FCEV) - long-type cooling liquid heater for indoor heating of environmentally friendly vehicles (EV, FCEV).

  Function: It is a method of using surface heating elements (ReP) to heat the cooling liquid and serve as a battery heater to maintain the battery temperature for heating - integrates the heater part and control part together, achieving compact packaging and protection function for high voltage equipment.

Distribution of Woory Electronic Products

2. Project Background Introduction

In the fiercely competitive automotive industry, Tianjin Woory Electronics focuses on the manufacturing of automotive air conditioning systems and electronic components, continuously improving production efficiency, ensuring product quality, meeting diverse customer needs, and achieving refined management in the production process. To better connect with original equipment manufacturers and enhance product capabilities, it also required the company to be equipped with the MES system at the request of its client "Xiaomi," as previously, it relied solely on ERP for bookkeeping, lacking quality traceability systems, production process tracking, effective performance systems, and more. Therefore, the MES system was introduced to address current pain points and enhance the company's core competitiveness to adapt to the rapid development needs of the automotive industry.

3. Business Process

3.1 Production Process

Assembly Business Process

4. Project Blueprint (Goals)

1. Build Efficient Information Transmission Channels ◦ Achieve material distribution scheduling based on workshop plans, execution, and efficient delivery of production materials combined with precise inventory management, improving production logistics efficiency and reducing workshop inventory. Involves information interchange and collaborative work among production, purchasing, and other departments. ▪ Output input does not match proportionately, solve the missing parts issue

2. Establish a Comprehensive Production Monitoring System ◦ Achieve real-time control of production task progress - consolidate work order progress with inspection progress, process mistake-proofing. By real-time monitoring of production work progress, achieve visualization of the production process. ▪ Preventing material feeding errors ▪ Scanning error of serial numbers ▪ Starting downstream execution without the completion of upstream processes, leading to process omissions (due to handover)

3. Optimize Production Planning Scheduling ◦ Achieve multi-level flexible dispatch of production tasks, automatic or manual production progress statistics, monitoring, overdue reminders, and cause analysis, and support multi-dimensional production statistical reports to help companies improve on-time delivery rates. ▪ Lack of analysis and review of overdue situations ▪ Analysis of production plan achievement rates ▪ Lack of flexibility in workshop scheduling adjustments

4. Strengthen Quality Management Functions ◦ Achieve batch/SN code management for finished products, semi-finished products, and raw materials, and collect quality data of key processes to solve the difficulty of material traceability. ◦ Establish a quality issue PDCA closed-loop to steadily reduce quality loss. ▪ Lack of FIFO control, electronic components are affected by temperature and humidity, prone to quality issues

5. Create a Complete Product Traceability System ◦ Record the process and results of after-sales repairs, provide spare parts traceability records, and interact with production testing software to achieve mutual access to quality and assembly master data, meeting regulatory and customer requirements for full lifecycle traceability of products. ▪ Trace raw material batches, sn ▪ New sn after rework must be bound with new sn ▪ Interactions of air-tightness testing, ccd, torque, and other equipment's production testing, data collection

6. Performance Management ◦ Core KPI statistics, more accurate feedback on factory status, helps accurately analyze existing problems.

Application of the Plan After (After)

5. Detailed Solution Process Breakdown

5.1 Supply Chain Management Solutions

5.1.1 Supplier Collaboration Management

Solution Introduction: By opening accounts for each supplier in the MES system and integrating with the ERP purchasing module, share purchasing information, increase the efficiency and data accuracy of the purchasing inbound business flow, breaking down data silos between purchasing/warehouse/suppliers, and forming a data closed loop.

Before Application (BEFORE)

• Confusion in Delivery Information: Disordered deliveries, the purchasing department has difficulty grasping the delivery situation, relying on offline bookkeeping for data sorting, which is inefficient and has delayed information.

  • Cannot track purchasing in transit, excessive purchasing leads to inventory backlog

• Warehouse Operations are Cumbersome and Prone to Errors: Warehouse manually counts goods, information entry relies on outdated delivery slips, entering information into the ERP system, and cannot do real-time warehousing. Increased business volume leads to increased errors.

  • Delivery slips backlog, counting errors

• Difficulties in Data Collaboration: Independent data systems for purchasing, suppliers, and warehouses, many disputes in checks affecting inbound audits and payment processes, hindering operational efficiency.

  • Purchasing has separate ledgers, warehouses have separate ledgers, and suppliers have separate ledgers; it is easy to have disputes when reconciling inbound quantities among the three parties

After Application (AFTER)

• Accurate Transmission of Purchasing Information: The MES system creates accounts for suppliers allowing them to clearly view the purchasing order information they are responsible for, achieving precise and efficient transmission of purchasing order information within the supply chain.

• Refined Control of the Delivery Process, Clear and Accurate Material Identification: **Suppliers perform operations in the MES system before delivery and print coded labels to enhance material tracking and management standardization.

  • Regulating supplier delivery actions at the operational execution level

• Optimized Inbound Process: The warehouse uses PDA scanning for inbound, increases efficiency, and creates complete and efficient data closed-loop.

  • Improving on-site purchasing inbound efficiency, avoiding backlog of inbound slips for reorganization

  • With upstream data support, processes become more efficient

Printing of Purchase Order QR Code

Receiving List

Warehouse staff receive the "Receiving Delivery Slip" printed by the supplier in the new kernel cloud system for quantity verification and scan the "Receiving Delivery Slip". The APP will display the total delivery amount, and the next step the warehouse staff scans the "Batch Label Code" on each packaging box for the inbound action.

Scanning for Inbound of Purchased Materials

Workpiece Identification Table (SN Code)

Batch Identification Label (Batch Code)

5.1.2 Material Identification Code Management

Solution Introduction: Pre-settings of key raw material SN rules provided by different suppliers in the system, avoiding the need for SN inventory checks during purchasing receipt. Quickly recognize raw material SN using one-click scanning at the production terminal and apply it to the production line as production process SN, enhancing flow efficiency while ensuring SN identification, binding, and traceability during production.

Before Application (BEFORE)

• **Difficulties in SN Inventory Check**: Woory has many suppliers with varying SN rules that are not in consecutive order, high cost of manual inventory checks, prone to errors, and traceability difficulties.

• Confusion in Production Mapping: In production, raw material SNs and product SNs are unclear, easily leading to errors in preparation and assembly, affecting capacity and production planning.

After Application (AFTER)

• System Identification Rule Setting: Pre-setting material identification code SN rules in the MES system, accurately identifying materials based on prefixes.

  • Mistake-proofing during material feeding and usage

• Convenient Purchasing Inbound Operations: During procurement, there is no need for offline organization of the SN list; it is completed by batch during inbound.

  • Batch inventory, saving customer inventory workload

• Smart Management of Material Feeding: After production feeding, scanning generates work-in-process SN, automatically binds related raw material SNs, and corrects errors.

Serial Number Configuration

Material Identification Code

Open Material Identification Code and Verification Rules

5.1.3 First-In-First-Out Management

Solution Introduction: Enable the "Batch Management" of materials in MES systems, through batch information, recognize the first-in-first-out sequence of materials to prevent inventory backlog, improve turnover rate, and reduce losses from stagnant materials.

Before Application (BEFORE)

• Old System Lacks Batch Management: Woory's original UNI-ERP system managed only inventory quantities, lacking batch management, leading to shipments not adhering to first-in-first-out principles and affecting factory audits.

• Risk Control Difficulties: Due to the lack of batch management, quality issues with materials and recalls cannot be quickly addressed, causing multiple losses.

• Cost Increase Hazards: The initial lack of reasonable batch management hampers the traceability of raw materials, leading to inventory backlog and waste, resulting in increased costs.

• Quality Stability: Electronic components can easily become stagnant due to environmental impacts, risking product quality due to outdated components.

• Inventory Counting Challenges: The absence of batch management complicates inventory checks and prevents accurate statistics of batch product details, affecting purchasing and production planning.

After Application (AFTER)

• Raw Material Batch Management Standardization: Inbound semi-finished products and raw materials can start batch management as suppliers label according to requirements, and Woory's warehouse scans in and out accordingly.

• Finished Product Batch Management Process: Self-manufactured finished products start batch management; the production packaging and inbound and outbound operations must follow the respective scanning rules.

• First-In-First-Out Guidelines Execution: Configure first-in-first-out standards to check outbound sequence based on batch serial numbers; if the current batch does not comply with the FIFO rules, report an error: "Current batch does not conform to first-in-first-out rules".

Configuration of First-In-First-Out Rules

Production Inbound Batch Number

Receiving Slip

Batch Identification Label (Batch Number)

Packaging Slip Number

Packaging Date

During the inbound process, the APP scans the "Material Batch Label". The new kernel cloud will save its batch number (filled in by the supplier, with the batch date being the actual production date of the supplier's materials); during subsequent outbound, the warehouse staff will still scan the batch label. If the batch number of that label is not the earliest serial number, outbound is not allowed, prompting, "Not following the first-in-first-out rules for outbound."

Raw Material Scanning for Inbound (Infrared scanning and camera scanning are supported)

Scanning for entries and exits connects to receiving orders and shipping orders, using PDA to scan the supplier’s inbound slip/sales shipping slip to quickly locate the inventory tasks, then scan the box code for outbound and inbound operations.

5.2 Workshop Production Management Solutions

5.2.1 Workshop Planning Management

Solution Introduction: The MES system, through real-time monitoring and automated scheduling, can quickly respond to demand changes, raw material supply issues, and other unpredictable factors, adjusting production plans to accommodate new circumstances. This flexibility allows enterprises to better cope with various changes in the production process, ensuring the smooth execution of production plans.

Before Application (BEFORE)

• Deficiencies in Plan Communication and Response: Paper plans distributed to the workshop have poor timeliness, struggling to cope with unexpected situations and urgent requests on-site, resulting in low scheduling efficiency.

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• Inter-departmental Plan Collaboration Obstacles: Paper plans from multiple departments are updated unsynchronized, severely affecting business collaboration efficiency.

• Difficulties in Plan Retrieval: Paper plans are inconvenient for retrieval; during peak production seasons, workshop supervisors find it time-consuming and error-prone to query, impacting decisions.

After Application (AFTER)

• Accurate Planning: Production staff, based on workshop capacity, order demand, and other factors, precisely formulate production plans in the ERP system, seamlessly synchronizing to the MES via API, providing accurate action guidance for all links.

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• Aggressive Response: Once there’s a change in orders or production conditions, adjustments can be made swiftly at the planning center, with the system automatically linking to modify process plans in real-time, allowing production lines and work-in-process areas to adapt quickly ensuring production continuity.

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• Material Collaboration: In the work warehouse, materials are precisely picked and prepared according to production task orders, achieving perfect matching with production pace to eliminate waste and delays.

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• Transparent and Visible: From plan issuance, material ticket reporting to finished product output, all information is real-time accessible, process delays, overdue orders are clear at a glance; authorized users can precisely control production dynamics anytime.

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• Efficient Execution: Workers report production by scanning according to the process, real-time binding of material consumption and finished product information, the MES gives immediate feedback on production results to the ERP based on the last process report, forming an efficient execution closed loop.

Current Scheduling

Plan Achievement Rate

5.2.2 Workstation On-site Management

Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. At the same time, the system sets various mistake-proofing scenarios, such as stopping defective products, avoiding duplicate scans, ensuring production accuracy. Additionally, due to complex electronic industry needs, the solution supports SN replacement, SN comparison, auto-printing of SN, and more, enhancing flexibility and efficiency in production operations. The direct recognition of external SN barcodes also provides convenience for clients managed by the MES system, allowing seamless integration of raw materials’ SN/batch procurement inbound operations by scanning directly on the workstation page.

Before Application (BEFORE)

• Statistical Difficulties in Production Progress: Offline scanning binding on the production line requires terminal search for SN codes to check progress, unable to quickly summarize, the process is not transparent.

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• Deficiencies in Mistake-Proof Management: The site lacks mistake-proof measures, often causing assembly and material errors affecting production quality.

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• Information Absence in Material Consumption Management: Only manually querying finished product SN raw materials and batch material consumption, unable to locate, lacking production material consumption management.

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• Poor Quality Traceability Efficiency: For returned products, rely on terminal checks to trace back via excel sheets, time-consuming and lacking complete information.

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• Delayed Reporting of Production Actuals: Employees report production actuals offline with a summary, not timely and low accuracy, with data that is non-real-time.

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• Confusion in Serial Number Management: Producing finished product serial numbers offline generates duplicates, leading to stock issues at customer sites —> Logistics costs of returns borne by Woory.

After Application (AFTER)

• Convenient Reporting Mechanism: Employees scan SN codes to quickly jump to the work order reporting work, with operations being convenient and efficient.

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• Setting of Mistake-Proof Scenarios: The system sets various mistake-proof scenarios to prevent defectives and errors during scanning.

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• Material Inspection Assurance: The system verifies the uniqueness of materials, mistake-proofing and ensuring the accuracy of material consumption operations.

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• Quality Traceability System: Achieve forward and backward full-process quality traceability through the closed-loop data of the system.

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• Progress Display Function: Collect production testing data uploaded to the system, display production tasks and progress on boards/PC.

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• Material Scanning Error Correction: When scanning materials with wrong digit counts, the system prompts for corrections and rescan.

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• Serial Number Duplicate Control: When a duplicate serial number is scanned, the system prompts to avoid duplicate number scenarios.

Scan Serial Number (Mistake-Proofing)

Scan Binding to Production Order

Scan Material Code

Production Reporting (Mistake-Proofing)

Production line employees assemble and produce at their respective positions; when a single product is completed, they scan the material serial number in the new kernel cloud system for reporting.

SN Single Item Production Reporting

Woory Production Process

When upstream processes of products forget to scan to report work, downstream processes will prompt that the current serial number has not flowed to this process, therefore not allowing production reporting, resolving the production/testing omission scenario at the workshop scene.

Process Omission Preventing Proofing

When different Woory products report the same serial number, the new kernel cloud automatically conducts duplicate checks to avoid multiple products being bound with the same serial number sent to clients.

Process Duplicate Preventing Proofing

🚀 Product Data Package Link:A | Workstation On-site Management

5.2.3 Material Identification Code Management

Solution Introduction: Pre-set the key raw material SN rules provided by different suppliers in the system, eliminating the need for SN inventory checks during inbound, quickly recognizing raw material SN by one-click scanning at the production terminal, and applying it in the production line as production process SN, improving flow efficiency while ensuring production process SN identification, binding, and traceability.

Before Application (BEFORE)

• During raw material procurement, each supplier provides different material SN rules, and the SNs during inbound are not all in consecutive numbers. Manual inventory during Excel checks occupies significant manpower and time costs.

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• In production, the mapping relationship between the SN of raw materials and the SN of finished products is unclear (for example: there are several models needed for Product A, looking the same could lead to mistakes in preparing materials, and once input into the production line, employees sometimes cannot distinguish whether the model of raw materials used is incorrect and directly proceed with assembly), resulting in discovering that the material model (SN) used is not the raw material for that finished product after completing some assembly, resulting in rework and dismantling, seriously affecting employee capacity and execution of the production plan.

After Application (AFTER)

• In the new kernel cloud MES system pre-set material identification code SN rules, different materials have corresponding identification prefixes, and the system accurately identifies materials through these prefixes.

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• During purchasing inbound, there is no need for offline organization of the SN list; directly complete inbound by batch.

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• After production feeding, scanning primary raw material SN generates work-in-process SN (generation method: feeding SN, identification method: material identification code), and the consumption of other SN/batch raw materials is automatically bound with the primary raw material SN.

Serial Number Configuration

Planned Materials

Material Identification Code

• Different product serial numbers have different digit counts (all generated offline). To prevent the production line from reporting the wrong serial number, the new kernel cloud provides digit verification function;

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• Production line team leaders configure unique serial number digit counts for different product processes in the system. When scanning the serial number for reporting if the digit count does not match the preset count, it will report an error indicating that the scanned product/serial number is incorrect, prompting production line employees to correct it.

5.2.4 Packaging Management

Solution Introduction: The packaging management solution provides flexible packing methods and mistake-proofing rules, allowing production supervisors to print package codes in advance, and on-site workers can scan to package, while the system automatically records and binds product information, ensuring accurate packaging. The mistake-proofing rules can be set based on materials, work orders, workstations, etc., avoiding packaging mistakes. The traceability function can effectively locate and resolve issues.

Before Application (BEFORE)

• Disadvantages of Manual Packing: Workshop manual operations record packaging information, which is prone to errors, long cycles, and high costs.

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• Lack of Mistake-Proof Measures: The packaging process lacks control, and without mistake-proof measures, frequent errors in packing lead to affecting quality and efficiency.

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• Packaging Traceability Challenges: Insufficient real-time monitoring and traceability of packaging inhibit locating issues efficiently, hindering goods tracking.

After Application (AFTER)

• Customizing Packaging Strategy: Develop strategies according to product characteristics, covering quantity, rules, completion conditions, and more.

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• Establishing Mistake-Proof Rules: Set multi-factor mistake-proofing rules to enhance packaging precision and reduce errors.

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• Efficient Delivery Process: Scanning operations in production and warehousing increase delivery efficiency and shorten delivery times.

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• Temporary Storage Management Mechanism: Store information in the MES system during the last packaging to facilitate the continuation of packaging operations.

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• Real-Time Detailed Traceability: The digital system monitors packing, achieving traceability of full boxes, enabling rapid issue resolution and reducing delays. The MES system supports the traceability of product serial numbers inside boxes, and the handling of anomalies can be traced.

Inventory Details

Production Packaging

Packing Strategy Details

Mistake-Proof Rules

Packaging Records

Mistake-Proofing

Box Number Generation Rules

Packing Strategy

Packing QR Code

Temporary Storage Document

🚀 Product Data Package Link:A | Packaging Management

5.2.5 Full Process Traceability

Solution Introduction: The full-process traceability solution covers the entire production process from material entry to finished product sales. With one-code traceability support, it can trace every manufacturing step and related information of a single product, enabling real-time viewing and positioning of SN information for management during the process, and supporting reverse and forward traceability for post-management, helping quickly locate and manage issues during production.

Before Application (BEFORE)

• Difficulties in Missing Traceability Information: In the past, Woory could not accurately record each product’s production process and historical records, making it impossible to effectively trace a product’s origin, manufacturing process, and flow situation.

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• Unclear On-Site Information Issues: Difficulties in accurately knowing the production status, quality status, and lifecycle of products at the production site affect production decisions and quality control.

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• Difficulties in Locating Issues: When product quality issues or recalls occur, quickly locating the affected product range and causes is challenging, often leading to disputes.

After Application (AFTER)

• Recording and Traceability of Full Process Information: The system records all operational information for each product from material entry to finished product sales, including production, inspection, and packaging phases to enable comprehensive traceability.

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• Real-Time and Accurate On-Site Information Presentation: Provides timely and accurate operation information at the production site, helping production supervisors understand the production status and quality status of each product clearly.

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• Rapid Location of Issues and Loss Prevention: During product quality issues or recall events, the system can quickly locate the affected product range and reasons, reducing the scope of the issue and loss.

Production Details

Traceability by Module

Inspection Results

🚀 Product Data Package Link:A | Full Process Traceability

5.2.6 On-site Exception Management

Solution Introduction: The on-site exception management solution provides a fast setup for customized exception management processes, establishing clear responsibilities for exception response and handling mechanisms, improving the efficiency of solving exceptions, and reducing occurrences from the root to ensure smooth operation of the production plan.

Before Application (BEFORE)

• Problems of Traditional Communication: Woory's workshop often encounters exceptions such as material exceptions, process exceptions, safety exceptions, quality exceptions, equipment exceptions, etc. Currently, traditional communication via phone, WeChat, or paper documents offline leads to easy loss or incompleteness of exception event information with slow response speeds.

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• Lack of Quantifiable Performance Management: The speed of resolving exception incidents on site is unrecorded and managed, making it difficult to quantitatively analyze and improve the performance of the responsible personnel.

After Application (AFTER)

• Front-line employees or team leaders report exception events directly by selecting exception types through the MES system, describe exceptions, and upload photos; the exception event sets a timed upgrade process, with real-time reminders of event upgrade information to the current responsible person; supports exception handling performance and response speed analysis that managers can check with one click.

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• For Woory, manual upgrades for exception events and automatic upgrades for timeouts are set, ensuring a rapid response to restore production.

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• Exception reporting information is standardized, with clear descriptions and support for uploading photos, and reported records are traceable.

Exception Reporting

Exception Handling

Workshop production employees or the engineering department report on-site exceptions such as quality, lack of materials, and equipment exceptions via the new kernel cloud APP, pushing it to relevant resolution personnel. After resolving, this personnel reviews and reports the resolution process and results for handling exception events and traceability.

Exception Reporting

5.3 Quality Management Solutions

5.3.1 Incoming Material Quality Management (AQL)

Solution Introduction: Ensure product quality and ensure subsequent production efficiency and quality levels through a standardized incoming quality inspection plan.

Before Application (BEFORE)

• Issues with Missing Quality Inspection Data: During material inbound, the quality department performs offline inspections without defective records or supplier data, making it difficult to filter suppliers.

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• Insufficient Batch Material Information Records: The quality process does not record batch material information in detail, making it impossible to isolate defective raw materials entering the production line, thus affecting production.

After Application (AFTER)

• Binding Inspection Specifications to Materials: Use MES to bind the AQL inspection specifications and plans to each material, setting standards and norms for materials that need inspections.

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• Orderly Development of Inspection Processes: During inbound, the warehouse reports inspection by batch, and the quality department receives inspection tasks on mobile devices. The system generates inspection sheets based on supplier delivery status in real-time.

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• Efficient Handling of Defect-Proof Standards: The quality department conducts material inspections based on batch receiving inspection sheets, with inspection results reported through scanning. If defects are encountered, processes are triggered for handling defective items (partial return, full return, sorting, supplier sorting).

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• Supplier Management Based on Evidence: Display good rate stats of each supplier’s incoming materials in real-time, facilitating evaluations and penalties for supplier quality management, also plays a decisive role in selecting quality suppliers.

Inspection Specifications

Inspection Plan

Inspection Status

Inspection Records

Inspection Materials

🚀 Product Data Package Link:A | AQL Inspection

5.3.2 Quality Control During Production

Solution Introduction: To collect real-time quality data during the production process, identify quality anomalies promptly, and feed them back to relevant personnel for rapid measures. Accurately set and execute production process parameters to ensure that products are produced according to standard processes, maintaining quality stability; trace product information across production phases including raw materials, equipment, and personnel operations, and facilitate analysis of root causes of quality issues. Provide operational guidance and quality standards to operators, reducing quality problems caused by operational errors. Based on system data and analysis results, promote continuous quality optimization and improvement.

Before Application (BEFORE)

• Quality Records and Analysis Shortcomings: On-site process quality records are incomplete, comprehensive quality analysis is lacking, which is unbeneficial for quality enhancement.

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• Low Efficiency in Quality Inspection Data Processing: Some quality inspection data is collected on-site through production testing equipment, the processing flow is offline, resulting in low efficiency and long cycles for quality handling; also, the considerable amount of data on quality statistics is scattered across various workstation terminals, lacking data sharing, affecting the efficiency of statistical analysis, making issues difficult to close-loop.

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• Poor Quality Traceability Efficiency: When a product has quality issues, tracing back to SN/batch is time-consuming and inefficient.

After Application (AFTER)

• Efficient Transmission of Inspection Data: Checks/inspections through collection methods are passed to the MES generating inspection records, automating the flow and improving process efficiency.

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• Consolidation of Manual Inspection Information: Manual inspections are reported through a scanning quality inspection approach, connecting inspection reports and non-conformity reports uniformly viewed in the MES system, reducing information delays.

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• Quality Reporting for Analysis Assistance: Generate details on quality anomalies, counts of quality anomalies, statistics of responsible parties, non-conforming item rates, etc., helping build a database for continuous monitoring and analysis of quality.

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• Precise Full Process Traceability: The full process tracing by the system, forward tracing: from product series numbers traced from top to bottom, tracing its components and production process information; reverse tracing: the batch numbers of components or raw materials used in the product traced from bottom to top for all products using this batch of parts or raw materials, achieving finer granular traceability.

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• Dimensions of Production Testing Data Display:

  ① Production testing data summary

  ② Torque/air tightness/reliability and other quality parameters for online viewing queries

  ③ Consumption of raw materials’ SN tracing

  ④ Collection and analysis of source files from production testing equipment

  ⑤ KPI report output

Tracking Number

Production Testing Data

Production Testing Material Consumption

Production Testing Data Related Files

Air Tightness Data

Production Testing Data

File Detailed View

Production employees scan critical materials (aluminum shells) serial numbers during the first process and report at this workstation by scanning.

On-Site Scanning for Reporting - First Process

Production employees scan critical material (aluminum shells) serial numbers and raw materials’ (PCB) serial numbers for consumption binding reporting.

On-Site Scanning for Reporting - Feeding Process + Scanning for Consumption

Production employees scan critical material (aluminum shells) serial numbers and raw materials’ (high-pressure lines) serial numbers for consumption binding reporting.

On-Site Scanning for Reporting - Feeding Process + Scanning for Consumption

5.3.3 After-Sales Repair (RC)

Solution Introduction: The after-sales repair management solution implements systematic management throughout the entire process, including online recording of after-sales repair data, real-time following of after-sales progress, independently managing after-sales work orders and reporting pages, ensuring a structured execution of after-sales processes. Additionally, the system documents the entire disassembly and assembly processes, guaranteeing the reliability and traceability of after-sales services.

Before Application (BEFORE)

• Missing After-Sales Repair Records: Woory lacks a clear record of the after-sales repair processes, relying entirely on offline management without clear repair progress, causing chaotic management.

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• Confusion in Work Order Identification: After-sales work orders can easily be mixed up with regular work orders, lacking clear identification, leading to issues in distinguishing materials offline, causing abnormalities in the after-sales process.

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• Difficulties in Recording Key Information: The after-sales process requires recording problems with materials, repair history, and material replacements, with offline records being slow and prone to omissions.

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• Severe Lack of Process Control: Currently, offline after-sales repairs lack special process control, executing based on actual conditions with arbitrary disassembly.

After Application (AFTER)

• Complete Online After-Sales Management: Perfect the after-sales repair process, managing the entire after-sales repair process online, providing a complete flow from problem assessment, process repair to product return, helping solve transparency issues and data deficits in the after-sales repair process.

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• Reliable Disassembly Preventing Proofing: Material disassembly proofing prevents errors; the system automatically displays records of finished material assemblies, preventing employees from misdisassembling or incorrectly disassembling materials, ensuring the reliability of the rework process.

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• Independent After-Sales Work Orders and Processes: Provide independent functions for managing after-sales work orders, setting up unique after-sales processes for after-sales materials and independently reporting work for after-sales materials. Specific after-sales rework processes, planned materials, etc., are established for after-sales repair materials.

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• Enhancing Independent Work Order Functions: Set independent after-sales work order management functions for after-sales materials and manage them independently.

Production Progress

🚀 Product Data Package Link:S+ | After-Sales Repair Management

5.4 KPI Reports

5.4.1 Production Plan Achievement Rate

Solution Introduction: The plan achievement rate KPI report; data-driven decision support can improve the accuracy of production plans. By analyzing the plan achievement rate, Woory’s production managers can identify potential risks in production plans, taking measures for adjustments in advance, thus increasing the executability of the production plans.

Before Application (BEFORE)

• Transparency Issues in Production Progress: Lacking an analysis report for plan achievement rates, production progress is opaque, making it difficult for workshops and departments to understand the gaps between production and plans intuitively. The connections between the second and third floors’ workshops have no report reflections, causing production delays due to untimely delivery of semi-finished products.

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• Difficulties in Resource Assessment and Performance: Absence of plan achievement reports makes it impossible to accurately evaluate resource usage, making it hard for workshop directors to reasonably schedule worker duties, and there are no objective indicators to measure individual and team contributions to production plans, making it difficult to evaluate worker performance effectively.

After Application (AFTER)

• Clear Presentation of Progress: The production plan achievement rate report presents a clear comparison of actual and planned progress at each production stage, production line, or product, aiding workshop management in precise decision-making.

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• Convenient Tracking of Process Connections: For products with complex processes, reports can track the conditions of various process connections, precisely pinpoint delayed processes, and facilitate resource coordination in advance to ensure smooth transitions.

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• Precise Allocation of Workshop Resources: Based on the achievement rates and employee capacity analyses from each workshop and production line, flexibly arrange workers; during peak seasons, leverage reports to analyze the causes of low plan achievement rates, such as worker numbers or skill issues, to target hires or training to enhance efficiency.

Daily Production Report

Daily Production Report

Production Task Overview

Daily Progress

Employee Capacity Table

🚀 Product Data Package Link:B | Production Achievement Rate

5.4.2 First-Pass Yield Rate

Solution Introduction: The first-pass yield rate report. The MES system’s production/quality collection situation provides the first-pass rate report, offering visual data metrics for Woory’s subsequent quality management optimization methods.

Before Application (BEFORE)

• Lack of First-Pass Rate Statistics: Unable to effectively calculate and monitor the first-pass rate, causing Woory to face difficulties in quality supervision, cost increases, and fluctuations in production efficiency.

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• Quality Monitoring Gaps: Difficulties in timely detection of production-line quality issues between the workshop and quality department, unaware of overall product quality, impacting quality audits with clients.

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• Quality Fluctuation Hazards: For example, when producing products for Xiaomi continuously, lacking first-pass rate reports complicates quality stability monitoring, hindering effective quality enhancements.

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• Raw Material Waste Crisis: A low first-pass rate leads to raw material waste; without understanding pass rates, defective products’ raw material disassembly leads to waste, coupled with over-purchasing and increased costs.

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• Shortcomings in Employee Incentives: Lacking intuitive first-pass rates makes it hard to measure employee work quality and incentivize them, hindering the construction of a quality culture.

After Application (AFTER)

• Real-Time First-Pass Rate Reports Generated: Utilizing production testing data collection, output real-time reports based on first-pass formulas, making the production progress and quality status clear at a glance.

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• Accurate Quality Monitoring Upgrades: Using the new kernel cloud first-pass rate reports, gain precise insights into the quality of production segments, product models, and production lines, quickly locate defects and risks for timely improvements.

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• Periodic Quality Trend Tracking: Observe first-pass rate trends weekly, monthly, and quarterly to provide early warnings of defect causes, covering equipment, raw materials, and operational factors to flexibly adjust strategies.

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• Quality Objectives and Optimization Promotion: Set quality targets based on the first-pass rate; compare data from different batches and production lines to uncover advantages and promote them to other production lines for overall enhancement.

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• Quantifying Employee Performance for Incentives: With first-pass rate data support, provide objective and quantifiable performance indicators for production employees, fostering a healthy competitive atmosphere in quality between production lines and teams.

First-Pass Yield Rate

Process Target Yield Comparison Table

🚀 Product Data Package Link:B | FPY First-Pass Yield Rate

6. Application Value

Woory Electronics has achieved significant results in digital transformation, summarized comprehensively as follows:

• Product Mistake-Proof Management: Successfully implemented an efficient mistake-proofing process to ensure correct assembly during production, preventing assembly errors or omissions, thus avoiding the influx of defective products into the market. Furthermore, the system retains detailed records of product serial number (SN) information, providing reliable data support for product quality traceability.

• After-Sales Repair Management: Online management of the entire after-sales repair process providing a complete flow from problem assessment, repair process to product return, helping address pain points of transparency issues and data deficiencies during the after-sales repair process; also ensuring orderly progression of the after-sales repair process.

• Full Lifecycle Management of Parent Products: Comprehensive management throughout the various stages of production, usage, and maintenance of parent products, covering personnel, machines, materials, methods, and environment. This full lifecycle management model enhances product reliability and market competitiveness.

• Packaging Management: Woory achieves real-time monitoring of the packaging process and complete box tracing through the new kernel cloud while quickly positioning issues and taking action, greatly reducing unnecessary information delays.

• Full Process Traceability Management: Realized the entire production process from procurement to finished product sales, with unified traceability support allowing tracing of all production steps of a single product and corresponding information, real-time management of SN information viewing and positioning, and supporting both reverse and forward traceability, solving core issues in production/quality processes related to difficulties in tracking and chaotic data.

• On-Site Exception Management: Achieved quick setup of customized exception management processes, establishing a clear responsibility mechanism for responding to and addressing exceptions, enhancing the efficiency of resolving exceptions, and reducing their occurrences from the root, ensuring smooth production planning.

• Production Quality Management: Through real-time collection of quality data during the production process, promptly identifying quality anomalies and responding rapidly. Accurately setting and executing production process parameters ensure products are produced according to standard processes, maintaining quality stability; accurately tracing product information across various production phases, including raw materials, equipment, and personnel operations, facilitating the analysis of the root causes of quality issues. Based on system analysis results, providing decision-making data support for continuous quality optimization and improvement.

• Production Cost Control: More precise monitoring and control over production costs with real-time data analysis and cost predictions, allowing timely adjustments to production strategies and optimizing resource allocation, ultimately reducing overall costs.

• Smooth Interaction with Production Testing Software: Seamless integration between production systems and testing software permits quality master data and assembly master data to be mutually accessible, accelerating issue response speed.