TOTAL DOOR: Technology Implementation Lays Groundwork for Future Innovations
The integration of Tulip has become about more than just our digital work instructions. We have found multiple opportunities to improve our efficiency and our precision. We will be feeling the impact of our work for years to come.
-- Jeanne Kitchen, Chief Operating Officer
Total Door Systems (www.totaldoor.com) is the global leader in fully integrated door systems that provide unparalleled security and unmatched reliability with a nearly infinite selection of design options. From its beginning half a century ago, Total Door Systems was founded on innovation, and built their business and processes around integrity, efficiency, sustainability and world-class service. All parts are engineered, manufactured and assembled at their award-winning Waterford, Mich., plant, where they employ 46.
Challenge
In an industry where precision and quality are paramount, Total Door Systems faced hurdles that were limiting their operational efficiency. Specifically, they encountered:
• Analog Work Instructions: Using paper-based work instructions was time-consuming and led to confusion among employees, affecting productivity and quality.
• Fragmented Data Collection: A mix of analog and digital data collection methods made it difficult to comprehensively analyze production efficiency and quality trends.
• Inefficiency and Quality Issues: These factors culminated in upticks in inefficiencies and quality problems.
Recognizing the need for change, Total Door Systems sought to implement a more intuitive and integrated solution that would streamline processes and enhance data visibility.
Solution
To address these challenges, Total Door Systems partnered with Michigan Manufacturing Technology Center (MMTC). MMTC performed a Technology Opportunity Assessment to identify technologies that would provide maximum improvements and ROI. After reviewing the various technologies available, licensed Tulip software was identified to provide the greatest immediate benefit, allowing for workflow digitization, automated data collection, and real-time insights. To ensure successful integration and implementation, MMTC provided onsite technology mentoring. This strategic move involved several key steps:
1. Digitizing Work Instructions: Total Door Systems transitioned from paper to digital work instructions, incorporating video elements and interactive components to improve attention and accuracy.
2. Enhancing Quality Inspection: The company applied Tulip software to its quality inspection processes, moving from paper-based inspections to digital documentation, including digital images of inspection results.
3. Optimizing Preventive and Predictive Maintenance: By exporting records from outdated systems to digital tablets, Total Door Systems enabled easy access to equipment manuals and maintenance records. Maintenance results were automatically recorded, providing a comprehensive view of the equipment’s health and performance.
With these initiatives, Total Door Systems not only improved operational efficiency but also laid the groundwork for future innovations. The Tulip platform became more than just a tool for digital work instructions; it evolved into a cornerstone of their digital strategy.
Results
- Cost Savings: $85,000
- Time Savings: 50% reduced manufacturing time due to improved process and quality initiatives