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Honda’s manufacturing facility required a streamlined, automated solution to ensure that every aspect of the production process met stringent quality standards. The previous system was manually intensive, prone to errors, and lacked centralized oversight, leading to inefficiencies in tracking quality control metrics, managing workflows, and maintaining consistency across production lines.

Success Story

Streamlining Quality Control with Automation

for Smarter Manufacturing

HBS Solutions, a growing energy audit company, faced multiple operational challenges due to manual and inconsistent processes. From inefficient scheduling to complex, error-prone calculations, these issues hampered productivity, increased costs, and affected audit accuracy. Technokeens partnered with HBS Solutions to develop a custom software solution that automated and streamlined the entire audit workflow, improving efficiency, reliability, and customer satisfaction.

Problem Statement:

Honda’s manufacturing facility required a streamlined, automated solution to ensure that every aspect of the production process met stringent quality standards. The previous system was manually intensive, prone to errors, and lacked centralized oversight, leading to inefficiencies in tracking quality control metrics, managing workflows, and maintaining consistency across production lines.

Solution

Technokeens developed Honda QGate, a comprehensive iOS app to automate and optimize the manufacturing quality management process. Key features of the app include:

  1. Automated Quality Tracking: Real-time tracking of quality data across various stages of production, ensuring consistent adherence to standards.
  2. Streamlined Process Management: The app automates task assignments and quality checks, minimizing human error and increasing process efficiency.
  3. Centralized Data Access: All quality-related data is stored and accessed through the app, enabling easy retrieval and analysis by relevant stakeholders.
  4. Real-Time Reporting: Instant access to performance and quality metrics allows quick decision-making and immediate corrective actions if needed.

User-Friendly Interface: Designed for ease of use, ensuring that factory floor staff can quickly adopt the app without extensive training.

Impact

  • Increased Efficiency: Automation of quality tracking and reporting reduced manual intervention, enhancing the overall production flow.
  • Error Reduction: The app minimizes human errors by automating quality checks and centralizing data.
  • Improved Decision-Making: Real-time access to quality data allowed managers to make quicker, more informed decisions on production processes.
  • Error Reduction: The app minimizes human errors by automating quality checks and centralizing data.
  • Improved Decision-Making: Real-time access to quality data allowed managers to make quicker, more informed decisions on production processes.
  • Enhanced Workflow Management: Streamlined process management improved productivity and ensured adherence to quality standards.
  • Better Quality Control: The app’s automated features allowed for thorough quality assurance across the production line, ensuring high standards were met consistently.
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Q-Gate

Related Success Stories

Challenges

  1. Inefficient Scheduling of Audits
    The audit scheduling process was entirely manual, requiring significant time and coordination. Frequent delays and rescheduling negatively impacted productivity and customer experience.
  2. Inconsistent Calculation Templates
    Energy Conservation Measure (ECM) calculations were done using various Excel sheets without a standard template. Different employees used customized formats, leading to data inconsistency and frequent errors.
  3. Complex, Error-Prone Calculations
    Each ECM involved unique formulas. Manual calculations in Excel were complex and highly susceptible to human error, risking the quality and reliability of audit results.
  4. High Operational Costs
    Manual processes for scheduling, calculations, and data management demanded more manpower and oversight, increasing overall operational costs and lowering efficiency.
  5. Manual Utility Coordination
    Communication and report submissions to utility companies were handled manually, slowing down approvals and creating additional administrative burdens.
  6. Data Management Challenges
    With no centralized system, managing the growing volume of audit data—photos, unit details, and project files—was difficult. This resulted in version control issues, data loss risks, and inefficiencies in data retrieval.

Solution

Technokeens delivered a custom cloud-based software solution hosted on AWS, designed to automate and optimize every aspect of the energy audit workflow.

  • Custom Software Development on AWS
    A scalable and secure cloud infrastructure ensures high performance, data protection, and flexibility for future expansion.
  • Role-Based Secure Logins
    The system features role-based access controls, allowing administrators to assign permissions based on user roles, enhancing security and operational clarity.
  • Centralized Data Management
    All audit-related data—unit details, photos, site notes—are stored in a centralized, structured database, enabling easy access, better version control, and reduced data loss risks.
  • Automated ECM Calculations
    Manual Excel-based ECM calculations were replaced with automated backend logic. This not only reduced human errors but also improved the accuracy and reliability of audit outputs.
  • Standardized Templates
    Built-in ECM templates ensure standardized, uniform calculations across all audits, eliminating inconsistencies and simplifying internal reviews and audits.
  • Automated Report Generation and Utility Submission
    Audit reports are automatically generated and can be submitted directly to utility companies via email, streamlining communications and saving time.
  • Mobile Application for Field Engineers
    Technokeens also developed a mobile companion app. Engineers on-site can now view project details, perform calculations, upload photos, and submit reports in real-time, improving field efficiency and data accuracy.

#1 Assemble the right team

We handle all aspects of vetting and choosing the right team that you don't have the time, expertise, or desire to do.

#2 Sprint planning

Sprint roadmap is a collective planning effort. Team members collaborate to clarify items and ensure shared understanding.

#3 Tech architecture

We break monolithic apps into microservices. Decoupling the code allows teams to move faster and more independently

#4 Standups & weekly demos

Standups, weekly demos, and weekly reviews make sure everyone is on the same page and can raise their concerns.

#5 Code reviews

Code reviews before release help detect issues like memory leaks, file leaks, performance signs, and general bad smells

#6 Iterative delivery

We divide the implementation process into several checkpoints rather than a single deadline.

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