Automotive Supplier Plock – Quality Assurance for Small Parts

Small Codes, Big Impact: How Plock Metallwerke Optimizes the Supply Chain Through Digital Tracking

The medium-sized supplier Plock Metallwerke, in collaboration with paiqo, has developed an innovative solution to improve quality assurance for small parts. By introducing digital tracking using tiny codes on each produced part, all important quality information is captured and stored in Azure (Digital Twin). Employees and customers can retrieve and analyze information about each part through an app as needed. Furthermore, AI-based methods are used to identify potential defective parts early. Seamless data exchange with Plock’s customers is possible along the entire supply chain (Industrial Data Space).

Project overview

The challenge

Quality assurance for millions of small parts in the automotive supply industry must be designed efficiently, with optimal use of limited resources.

Solution

Plock Metallwerke, in collaboration with paiqo, developed digital tracking using tiny codes (Digital Twin) for small parts. In addition to seamless data exchange along the entire supply chain, AI methods are also used to identify potential defective parts.

Benefit

The innovative solution enables efficient quality assurance, transparency, and long-term traceability of parts, improved competitive positioning, and resource savings through the use of artificial intelligence and digital technologies like Azure.

The challenge

Not only are automobile manufacturers under significant pressure to innovate, but companies in the supply chain must also constantly optimize processes and products to remain competitive. The supplier industry faces the challenge of efficiently managing the quality of millions of small parts. As a medium-sized company, Plock must find the best possible solutions with limited resources. The digitization of production processes is a crucial part of their strategy.

Solution

In collaboration with paiqo, Plock has implemented a traceability solution where each part is marked with a unique code and can be digitally tracked (Digital Twin). All relevant data is stored in Azure and can be retrieved and analyzed as needed. Paiqo’s data platform, based on the powerful Azure infrastructure, provides Plock with a scalable solution capable of managing and analyzing millions of small parts. The entire process can be integrated inline into ongoing production. This digital solution offers security, transparency, and enables efficient quality assurance for millions of small parts.

A crucial aspect is the integration of the Industrial Data Space concept, which enables seamless data exchange along the entire supply chain. Plock’s customers gain access to relevant data to optimize their own production processes, thereby increasing the efficiency and quality of their own manufacturing. A particularly innovative addition is the “Plock Avatar,” which performs digital assembly in the cloud. Here, parts are digitally matched, and potential incompatibilities are identified.

Plock uses Power BI to visualize data during production. The dashboard aggregates information from cameras and the code reader and displays it for various parameters. This simplifies internal quality assurance. Additionally, employees can use an app to read the code of each component and access the associated data.

Furthermore, AI-based methods such as anomaly detection and predictive quality are used to predict potential defective parts. It is now also possible to explain quality deviations.

Benefit

The introduction of digital tracking means that every small part can now be traced and inspected at any time, elevating quality assurance to a new level. Customers can read the code of each component and access the stored data. The data of the Digital Twin is available even years after the part has been delivered, ensuring long-term traceability.

Thanks to the scalable Azure platform and the implementation by paiqo, Plock was able to carry out the process efficiently and cost-effectively. The company is already planning to extend the process to additional components to increase the quality value for customers and save resources.

Digital tracking has also given Plock a clear competitive advantage. Each part is now inspected and provided with a “birth certificate,” which reduces returns. The company saves valuable resources and can position itself as an innovative and reliable supplier due to the optimized process.

Thanks to the use of artificial intelligence, Plock can identify potential quality issues early and take targeted measures to improve product quality and reduce scrap.

Plock’s success story demonstrates how the digitization of production processes and the use of innovative technologies like Azure and AI can help optimize processes, improve quality assurance, and achieve competitive advantages. Through the digital tracking of each part, Plock Metallwerke can offer greater transparency and security, both during production and years afterward.

For more information about the project, please visit the Microsoft website: Customer Success Stories.

“With our process, we have a clear competitive advantage: No part leaves our factory without inspection and a birth certificate. This provides our customers with real added quality value and reduces returns. We save valuable resources – and no one has to inspect 180,000 parts individually anymore.”
– David Soldat, Project Manager at Plock