Ngoc Khanh Wire and Cable

Ngoc Khanh Wire and Cable 3S MES Digital Transformation

Established in 1994, Ngoc Khanh is known as a prestigious wire and cable factory with 3 plants: Goldcup, JEIN, and CIVIL. The enterprise is currently a strategic partner of the Yazaki Group – a unit that provides components for Toyota, Nissan, and Mitsubishi.

Industry

Dây cáp điện
Quy mô

+200 Employees
Giải pháp ứng dụng

3S MES

The digital transformation story originating from a 10-year-old paper archive

From the very first days of operation, Ngoc Khanh’s products have always had to meet the most stringent standards from its exclusive customers. Therefore, the Ngoc Khanh factory has not only invested in advanced machinery systems imported from Germany – Italy – Japan but has also trained a team of skilled engineers with high specialization. In particular, a quality testing department with modern imported technological equipment (equivalent to a quality certification testing center) was also built to ensure the best control of indicators for each shipment. Recognizing the importance of product quality, every detail regarding product codes, quality specifications, and technical data of the electric cables has been stored by the enterprise in hard copy format to meet the specific requirements of the Yazaki Group. To date, this information archive is over 10 years old.

For Ngoc Khanh, quality is always the top priority. Currently, Ngoc Khanh needs to meet the strict requirements of our exclusive partner regarding traceability, quality management, and preserving data accuracy for up to 20 years. Meanwhile, our archives have filled up all the cabinets and are showing signs of deterioration

Mr. Nguyen Ngoc Toan

QA Manager, Ngoc Khanh

It was from here that the connection between ITG and Ngoc Khanh originated with an urgent challenge: Bringing Ngoc Khanh’s entire paper archive onto a digital environment, optimizing operational capabilities, and enhancing production quality.

The journey of identifying and building a unique roadmap for the project

Receiving the challenge from the customer, ITG immediately assembled a human resource team to conduct discussions and practical surveys with Ngoc Khanh. From there, in June 2021, the project to implement the 3S MES Manufacturing Execution System for Ngoc Khanh Wire and Cable was officially launched.

At the beginning, when approaching the project and conducting in-depth surveys, ITG was surprised to witness the massive scale of the enterprise's archives. Digitalizing these is not easy; Ngoc Khanh needed more than what they currently had...

Mr. Dinh The Hung

Project Director, ITG Technology

The challenges did not stop there; the project entered the launch phase just as the entire country was implementing social distancing, and all parties faced many difficulties in remote information exchange. This led to certain obstacles during the implementation process in accessing the specific production characteristics at Ngoc Khanh. Despite this, the project progress was excellently maintained by all parties as planned.

After more than a month of analyzing, testing, and recording the requirements set by Ngoc Khanh, we realized that production activities were facing data connection issues, causing difficulties in quality control from input to output. Consequently, the ITG project team set out core objectives to solve the production problems at Ngoc Khanh.

Mr. Bui Van Du

Project Manager, ITG Technology

A new version of Ngoc Khanh: Upgrade and Optimization

After a period of continuous partnership and relentless work, by the end of October 2022, the 3S MES system was officially and successfully applied at the Ngoc Khanh Wire and Cable factory. A new version of the factory was formed with an upgrade not only in machinery but also in operational processes.

Currently, the rooms filled with hundreds of paper file cabinets kept in the factory have been condensed into a convenient and optimized software system. This helps the management team easily grasp information and minimize unnecessary errors in controlling product and shipment quality information.

From hundreds of paper inspection forms, we now only need to store data with 4 functions for updating and reporting on a digital platform.

Mr. Ta Van Thong

Production Manager and Project Administrator, Ngoc Khanh

From here, the quality assessment process at all production workshops in the factory was established and automatically linked with the warehouse management section to conveniently eliminate substandard shipments. For the QA department, the system also allows employees to create in-depth analytical reports on product quality to identify existing problems at each stage.

Key Figures

8000

Forms

From departments that have been digitalized
200

Personnel

Proficient in computer usage
20%

Productivity Increase

Across the entire system operation
100%

Information

Fully traceable

In particular, there is no longer any data fragmentation; a seamless flow of information from the office departments down to the production workshops has been established. Specifically, after receiving an order, the planning department runs the production scheduling function, which is then automatically distributed to OI (Operator Interface) screens located at each stage. As a result, the quality of production operations in the factory has been significantly optimized compared to before.

Additionally, QR code/Barcode technology assists factory workers in easily recording the quantities of finished and semi-finished products at each production line in real-time. From the stages of raw material issuance, drawing, stranding, and coating to the final loss-calculation inspection, all have become more efficient with the presence of the 3S MES system.