Optimizing the Rework Area in an Automotive Parts Supplier Company by Digital Tools: A Foundation for Smart Industry Transformation

This article introduces the Lean Principles methodology for optimizing a “rework” area in an automotive parts supplier company using digital tools. The main objective is to reduce work-in-process inventory and eliminate waste in production processes. Hence, the improvement process analysis is divided into two phases. The first phase includes a process analysis and waste elimination. The second phase includes developing and implementing a software system for reworked material tracking. The software system allows precise control of materials in rework and collects valuable data in real time. Results indicate that the implementation of the proposed improvements and the software has positively impacted the efficiency and productivity of the “rework" area. Work-in-process inventory has been reduced by 20%, and the number of defective parts has been reduced by 15%. The improvements proposed provide the basis for creating a smart industry, as they help to improve efficiency, productivity, and quality using emerging digital technologies.