Cutting Warranty Costs: The Impact of Dozuki on Heavy Equipment Inspections

Inspections are very common when dealing with large equipment and high dollar value production.?

Maintaining the quality and condition of equipment before delivery is paramount in the industry.?

But manufacturing companies face significant challenges in documenting and tracking machinery conditions prior to shipment. Customer complaints about damages often leading to lengthy investigations, uncertainty, and substantial financial losses in warranty claims.?

Manual processes for capturing and filing inspection forms are not only cumbersome, but also prone to errors.

Integrating connected worker solutions into the Pre-Delivery Inspections (PDI) process can significantly enhance data capture, streamline operations, and reduce costs associated with warranty claims.?

Below, we’ll illustrate how this transformation is possible, supported by a compelling case study of a manufacturer who has effectively implemented these solutions.

Transparency Saves Cost & Boosts Credibility

A leading heavy machinery manufacturer needed to streamline their PDI process through digitized data capture and the use of worklog PDFs. This approach enabled the creation of detailed and easily accessible inspection records for each machine, including photographs and comprehensive documentation.

Here’s what happened.

The company received a customer complaint about a damaged unit. The customer claimed the machine was shipped with the damage. However, using their connected factory worker platform, the company was able to pull up the work order and show that the machine was undamaged when it left their facility. This evidence shifted the responsibility to the transport company, saving the company from a $70,000 warranty claim.

“It’s actually saved us at least twice in the past couple of weeks,” said the Quality Manager.

Ultimately, the transport driver admitted to causing damage after being presented with the worklog evidence. This transparency not only saved the manufacturer significant costs, but also helped maintain their credibility and trust with customers.

Without this information, the manager would have had to go back to the team on the floor and blame them for the damage. However, with accurate data, they can now precisely track and identify where the problem occurred.

Here are several action items for heavy machinery manufacturers:

Digitize Inspection Forms

Transition from manual to digital forms to ensure precise and consistent data capture. Utilize tools like Dozuki to create comprehensive inspection checklists that include photos and detailed descriptions.

Implement Photo Documentation

Incorporate photographs into inspection reports to visually document the condition of machinery at various stages. This provides clear evidence to support the quality and condition of products before delivery.

Utilize Worklog PDFs

Generate and store worklog PDFs for each piece of equipment. These documents should detail the inspection process, findings, and any corrective actions taken, serving as a reliable reference for future disputes.

Train Staff on Data Capture

Ensure that all employees involved in the inspection process are trained on how to use digital tools effectively. This includes understanding how to fill out digital forms accurately and take clear, informative photos.

Regularly Review and Update Inspection Procedures

Continuously assess and refine inspection protocols to address new challenges and improve efficiency. Regular reviews help ensure that the inspection process remains effective and up-to-date.

Leverage Data for Continuous Improvement

Analyze the data captured during inspections to identify recurring issues and areas for improvement. Use this information to enhance product quality and reduce future warranty claims.

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For heavy machinery manufacturing companies, integrating Dozuki into the PDI process is invaluable. The ability to capture and access detailed inspection data quickly transforms operations, leading to significant cost savings and improved customer satisfaction.

If you want to learn how Dozuki can help you adopt effective data capture methods to enhance you inspection processes and protect their bottom line, contact us today.