iLEAN cases for Tier-2 automotive metal stamping plants
Tier-2 plants stamping brackets, reinforcements and drawn arms for seating and suspension Tier-1s share one capital pain: zero PPM to the customer with IATF 16949 evidence alive every single day. Every case follows the same structure — the problem as it is lived at the press, the piece of iLEAN that solves it and the estimated impact. All are deployable piece by piece; you start with one, not with the whole platform.
Capture without changing habits: photo, voice, email, integrations
Paperless order startup
Payback 4-9 months · from 4-8 h of latency to zero
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Press curve without touching the PLC
Payback 5-10 months · press capex >US$400K deferred
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The steelmaker mill certificate, active
Payback 3-7 months · first-lot draw fracture, made predictable
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The process engineer's earpiece
Enabling piece: the living PFMEA is fed without typing
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Human validation in two taps
Enabling piece: nothing enters the ERP without a human signature
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From the lab spreadsheet to the ERP
Payback 4-9 months + −50/−80% quality-module licenses
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Photo of the delivery note and the steel coil
Payback 3-8 months · truck from 30-45 min to 5-10 min · −50/−70% licenses
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Shipping labeler stitched to the ERP
Payback 3-6 months · zero lot errors towards the Tier-1
See the case →Vision on the line: part defects and die changeover validation
Agents that document, coordinate and defend the audit
More cases from this series
- Every lot ships with its IATF dossier already madeEvery lot ships with an auditable dossier: order, coil, heat, press curve, first-off, last-off and CMM.…
- From the metrology spreadsheet to the ERP, without retypingDimensional readings move from the metrology spreadsheet into the ERP with no retyping — and…
- The steel coil enters the ERP with a photo, not with typed linesA photo of the delivery note and the coil tag puts heat, thickness and lot into the ERP: trucks leave in…
- The mill certificate stops being a PDF and starts being a controlThe mill certificate stops being a filed PDF: yield strength and elongation per heat are cross-checked…
- Production order startup, digitized with three photographsDigitize the production order, the IATF checklist and the first-off in one photo: the batch exists in…
- The mechanical press talks without touching its PLCA camera on the HMI turns peak force and strokes per minute into live data, with no PLC retrofit and no…
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