Case Studies: #VAL-001
Valeo Case
Global automotive manufacturer and supplier that utilised data from i-5O’s vision system to manage high employee turnover through enhanced visibility on the production floor
Overview
Valeo
Valeo is an automotive supplier and partner to automakers worldwide. As a technology company, they design innovative solutions for smart mobility, with a particular focus on intuitive driving and reducing CO2 emissions. Headquartered in Paris, France, the Group also provides and distributes spare parts for automakers and independent aftermarket operators. They have 175 production sites and 66 Research and Development centres in over 29 countries. i-5O Computer Vision System is deployed in their production facility at San Luis Potosi, Mexico where various automotive components are manufactured. San Luis Potosi is also a major hub that services automotive demand stemming from the U.S. and Germany. The video data generated by i-5O has helped the team at Valeo with precise root cause analysis and labour optimisation.
Problem
High employee turnover leading to a decline in production and inability to identify root cause for operational issues
Valeo has been experiencing a decline in production due to a shortage of labour and staff cuts, which has led to higher employee turnover rates and less experienced staff. Additionally, to assess productivity and efficiency on the manufacturing floor, Valeo was relying on manual time studies and partial data leading to incomplete and outdated results. Not only is it time consuming and impractical to conduct manual time studies, data collected is often inaccurate as operators tend to perform differently when being monitored by an industrial engineer. Due to the lack of visibility in their operations, Valeo has been facing uncertainty in identifying the root cause when issues arise, making it difficult to increase their production.
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Solution
i-5O introduced a Computer Vision System to provide Valeo with enhanced visibility and precise data analysis, addressing the shortcomings of manual methods
i-5O computer vision system was deployed on Valeo’s assembly line, continuously monitoring the performance of each worker on the floor. Through accurate real-time and video data the management was able to detect discrepancies and need for balancing workload on the line. Through detailed root cause analysis, it was identified that certain operations for the first part of the line required training to increase productivity. Based on data provided by the i-5O vision system, optimal layout plans were also drawn up for further efficiency gains. By eliminating the need for manual time studies and gaining access to accurate and updated productivity data, Valeo was able to better manage their workforce planning, improve efficiency and capacity utilisation.
Our Results
Potential to achieve productivity gains of over 80% translating into massive increase in revenue
Demonstrated increase in production capacity by up to 20% per assembly line
Accurate workforce planning and labour training requirements
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