Case Study
TK Elevator Sees 97% Issue Closure Rate with Quality Management System AI Advisor
0%
issue closure rate within 2 years of implementation
$0
million in reduced COPQ
0
day cycle time for issue resolution, down from 120 days
$0
million saved from identifying and fixing a critical design flaw
The Challenge:
TK Elevator, a global leader in mobility solutions, was facing significant inefficiencies in its quality management processes. With over 1,000 sales and service locations worldwide, managing quality concerns effectively across all teams was a daunting task.
Previously, TK Elevator’s quality issues were handled manually, resulting in long cycle times and high costs due to errors and inefficiencies. Field workers often had to report issues from memory after returning from site visits. This led to delays in addressing problems, often taking an average of 120 days to resolve, with a closure rate below 50%. As a result, the company was struggling with costly errors and missed opportunities for improvement.
- Long cycle times for resolving quality issues.
- Manual processes prone to human error.
- High costs due to delayed or unresolved quality issues.
- Difficulty in tracking and escalating concerns in real-time.
The Solution:
Benchmark Gensuite’s Safety Observations application supports behavior-based safety programs for real-time insights into safety risks in the workplace, and for promoting safe employee behaviors and work activities.
To tackle these challenges, TK Elevator partnered with Benchmark Gensuite to implement the Quality AI Advisor—a powerful digital tool designed to automate and streamline the quality management process.
The Quality AI Advisor enabled TK Elevator to:
Automate the tagging and escalation of quality concerns, significantly reducing manual work.
Provide field teams with a mobile-friendly solution to capture incidents in real-time, within 90 seconds.
Offer program managers full visibility into quality issues, allowing them to address concerns earlier and more efficiently.
Use AI to analyze trends and identify potential issues before they escalated, driving proactive improvements.
With the automation provided by Quality AI Advisor, TK Elevator moved away from inefficient spreadsheets and time-consuming committee reviews, empowering their teams to take immediate action in the field.
The Integration Wizards Computer Vision technology uses artificial intelligence in the form of a convolutional neuro network (CNN) to create a virtual map that analyses the total operational area and configures alarms for specified hazards, using live CCTV camera feeds from onsite video monitoring systems.
When the Integration Wizard’s technology identifies those occurrences from the live camera footage, the details are automatically submitted via API into the Benchmark Gensuite platform.
A concern reporting form is then created and notifications are sent out to key team members so that personnel can take immediate action whenever non-compliances are flagged. GE Power is leveraging Benchmark Gensuite’s pre-built dashboards to provide safety leaders with a comprehensive overview of all safety concerns logged via various methods, including not only through computer vision but also through desktop and mobile devices, to gain unprecedented visibility into near misses and identify improvement areas more efficiently and systematically.
The results of implementing Benchmark’s Quality AI Advisor were dramatic. TK Elevator achieved:
97% issue closure rate, up from less than 50%.
20-day average cycle time for resolving quality issues, down from 120 days.
$1.1 million reduction in Cost of Poor Quality (COPQ).
$20.2 million in savings from an engineering design change initiated by identifying an issue early in the field.
TK Elevator’s Head of Quality for North America, Michael Melnyk, noted that these improvements were not just about efficiency but also resulted in significant cost savings. “If you address these issues in a timely fashion, there is a real, tangible dollar savings associated with it,” he said.
Looking to streamline your processes, boost efficiency, and reduce costs like TK Elevator? Benchmark Gensuite’s AI Advisor can help you achieve these goals with ease. Discover how automation and AI can simplify your operations and deliver real savings. Take the first step toward more efficient operations. Request your demo today!
01
Create a Stronger Safety Culture with Behavior Based Safety Software
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Manage Incidents and Injuries
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Ensure Timely & Complete Corrective Actions
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Mitigate Workplace Hazards
Spotlight on Levin Sources, a Benchmark Gensuite Partner
Levin Sources is a global B Corp-certified consultancy that:
- Enables governments, businesses, investors, and civil society to build sustainable, valuable, and equitable minerals value chains in line with major voluntary and mandatory ESG standards.
- Provides expertise with 130+ minerals and metals.
- Executes projects in over 90 countries and regions around the world.
