Katcon Case

A leading global automotive manufacturer utilized i-5O’s vision system to reduce rework costs and eliminate the risk of recalls, through real-time process inspection and immediate corrective actions.

Overview

Katcon is a global leader in exhaust systems, thermal insulation, and advanced materials components. They offer high value add solutions in the gasoline, diesel, hybrid, and EV applications in markets such as motorcycles, ATV, construction/agriculture, on & off highway, and light & heavy duty. With world-class standards, impeccable engineering capabilities, strong commitment to quality, and global footprint, Katcon is positioned as a strategic and reliable supplier among the leading OEMs. Headquartered in Mexico, Katcon has manufacturing facilities and R&D centers around the world, led by motivated professionals from over 20 countries globally. i-5O Computer Vision System is deployed in their manufacturing facility in Poland where automotive parts ranging from exhaust, thermal insulation, and lightweight composites are manufactured. Real-time insights generated by i-5O’s AI vision system have helped the team at Katcon track operations and improve efficiency.

Problem

Inability to track processes and package shipments resulting in delivery errors. Manual time studies require time and resources. By the time results from time studies are received, it is often too late to implement changes due to the constantly and rapidly evolving business environment. Moreover, it is difficult to timely address issues that occur in production because of a delay in information processing. Katcon team wanted i-5O to help them gain visibility into their processes.

Solution

Implementation of i-5O computer vision system to provide unparalleled visibility and real-time tracking and process validation of manual operations. Katcon gained access to automated time study data and 100% accurate real-time insights into manual work processes throughout the production line. Implementation of the i-5O AI vision system allowed Katcon to have their data up-to-date, accurate, and customizable (i.e. raw data and power bi). Additionally, Katcon has the ability to adjust production according to their operational needs. To resolve their customer package accuracy and delivery challenge, the i-5O process validation module was implemented. This module provided an automated and reliable way to track the number of items allowing Katcon to ensure the correct number of products were being delivered to customers, reducing errors and improving brand reputation.

Our Results

50% reduction in downtime

Access to automated time study data

Significant decrease in delivery errors

“i-50’s system allowed us to reduce our planned downtime by 50%. Before using their system for each cleaning we allocated 10 minutes but based on the information we got from i-5O’s system, we were able to reduce it to 5 minutes”.
Katcon Production Manager

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