Nortek Air Solutions: Improving Quality and First Pass Yield with Poka
Nortek Air Solutions, a leader in air handling units, manufactures large, complex systems for clients in industries ranging from aerospace and biopharma to data centers and hospitals. With demanding quality requirements and a customer base that includes high-profile names like Facebook, Amazon and MIT, maintaining rigorous quality standards is critical.
To address inefficiencies in its quality control processes and improve manufacturing outcomes, Nortek implemented Poka’s connected worker platform. The results were remarkable: a 14% improvement in First Pass Yield (FPY), reducing defects and rework while enhancing overall operational performance.
Outdated Systems and Limited Accountability
Nortek faced significant challenges in its quest for quality. The company relied on paper-based quality checklists, known as Total Quality Control (TQC) forms, that lacked operator accountability.
“Our previous system relied on team leads signing off on 127 control points across four forms,” explained Eric, Nortek’s Lean Six Sigma Black Belt. “This approach often resulted in rubber-stamping, where the checks weren’t taken seriously, and supervisors felt powerless to enforce change.”
The paper-based process also lacked flexibility and visibility, making it difficult to track errors or identify recurring issues. These inefficiencies not only slowed down production but also jeopardized Nortek’s ability to meet stringent customer quality requirements.
Transforming Quality Control with Poka
Nortek turned to Poka’s connected worker platform to address these challenges, digitizing its quality processes and fostering a culture of accountability.
Key elements of the solution included:
Nortek replaced its four paper-based forms with 33 digital forms, significantly increasing the number of control points from 127 to 1,335. Operators now sign off on their own work, ensuring accountability and eliminating the rubber-stamping issue.
Poka enabled real-time data collection and analysis, allowing supervisors to track performance metrics and identify issues as they occurred.
When errors were identified, supervisors provided immediate feedback, linking the issue to the operator’s skills matrix. Operators who made repeated mistakes underwent retraining to reinforce their skills and ensure continuous improvement.
A 14% Improvement in First Pass Yield
By digitizing its quality processes and enhancing accountability, Nortek achieved a significant improvement in First Pass Yield, reducing defects and improving efficiency.
14% Improvement in FPY
Nortek’s First Pass Yield rose from 72% to 86%, demonstrating the effectiveness of its revamped quality system.
Enhanced Operator Accountability
Operators now take greater ownership of their work, knowing that their performance directly impacts their competency matrix and career progression.
Improved Supervisor Empowerment
Supervisors are equipped with actionable data and tools to address errors directly, making quality management more effective and impactful.
Operators now understand the importance of their work. The direct link between performance and progression has changed how people approach their jobs.
Eric Heuser
Quality and OpEx Director
Rolling Out Poka Across the Organization
Nortek implemented Poka in a phased manner, ensuring each stage of the rollout was optimized for success:
Initial Pilot
The company began with a single pilot line to test Poka’s capabilities and refine its approach based on real-world feedback.
Scaling the System
Following the success of the pilot, Poka was deployed across all production lines, with digital forms tailored to meet the specific needs of each customer and project.
Integrating Customer-Specific Requirements
Nortek incorporated customer-specific quality checks into Poka, ensuring all requirements were met without relying on informal knowledge or memory.
Driving Engagement and Accountability
Beyond the operational improvements, Poka catalyzed a cultural shift at Nortek, fostering greater engagement and accountability among employees.
“Operators now understand the importance of their work,” Eric explained. “When they make a mistake, it impacts their competency matrix, and they’re required to retrain. This direct link between performance and progression has changed how people approach their jobs.”
Customers have also noticed the improvements, with Nortek’s VP of Sales leveraging the enhanced quality checks as a selling point. The detailed forms, encompassing over 1,300 control points, demonstrate Nortek’s commitment to delivering high-quality products.
Key Takeaways for Manufacturers
Nortek’s experience with Poka offers several valuable lessons for manufacturers who want to improve their quality KPIs:
1. Digitize for Accuracy and Accountability
Moving from paper-based systems to digital platforms reduces errors, improves visibility, and fosters accountability.
2. Prioritize First Pass Yield
Focusing on improving FPY minimizes rework and boosts efficiency, delivering significant cost savings and quality improvements.
3. Incorporate Customer-Specific Requirements
Tailoring quality processes to meet unique customer needs ensures compliance and builds trust.
Ready to Enhance Your Quality Processes?
Nortek’s journey demonstrates the power of connected worker platforms to improve quality, accountability, and efficiency.
Contact our team today to learn how Poka can help your organization achieve similar results.