Carrio Cabling

Colorado-based Carrio Cabling wanted to improve the efficiency of its assembly line – it found that was just one of the benefits of WorkfloPlus.

Case Studies Intoware
Case Studies Intoware
Case Studies Intoware
Case Studies Intoware

Carrio Cabling Corporation is a Colorado Springs-based company which designs, engineers and manufactures custom moulded cable assemblies. Founded in 1988 by Glen Carrio, Carrio Cabling Corporation has been providing custom moulded cable assemblies to the oil, military and medical industries for more than thirty years.

With between forty and fifty assemblers working on several different customer orders at one time, it is common for one assembler to change between multiple different operations within a particular assembly several times a day, each with their own instructions or procedures. These transitions not only take time but risk introducing errors into the assembly process as staff shift between one set of paper-based instructions to another.

As well as replacing these paper-based processes with a digital solution, the management team also wanted a way to monitor the overall efficiency of the workforce in real-time. They hoped this would help them to identify assembly bottlenecks, as well as react quickly to any quality control issues or unforeseen problems that might slow down the assembly process. Clearly, it was time to find a better solution than paper and pens.

However, finding a replacement for paper processes was proving harder than expected. The company had looked at various software-based solutions over the years but had failed to find anything that had a modular approach to building workflows and tracking a one-piece flow on the production floor.

After doing research into new solutions on the market, Carrio decided to run a trial of WorkfloPlus. The plan was to run a one-month proof-of-concept with four assemblers using one of the most consistent assembly lines. In planning the trial and discussing it with the management team, it was estimated that it would take between 9-12 months to fully train staff and deploy WorkfloPlus across the business.

In fact, they found WorkfloPlus so quick and simple to use that half of the assemblers were trained and using WorkfloPlus in just six weeks.

Miles Carrio, son of founder Glen, was the engineer and team lead tasked with integrating digital workflows onto the production floor, explains how the shift to using WorkfloPlus was received. “Initially the staff were hesitant to any changes to their existing approach, but quickly found using WorkfloPlus to have big benefits over the old paper-based processes. Quite quickly, the assemblers themselves were coming forward with their own suggestions for changes to existing workflows, or even totally new ones that they felt would improve their efficiency even more. The great thing about WorkfloPlus is that you can build a workflow in 5 minutes, upload it and try it out then and there. So it’s incredibly easy to test, iterate and improve.”

Now the team is building at least 5 new workflows every day. The old paper-based system has been completely replaced with a digital platform with a data feed that can be analyzed in real-time. The team at Carrio then use it to generate hourly insight reports with a level of insight that was never previously possible.

“WorkfloPlus also gives our assemblers real insight into their own performance, as it can show how they compare to a benchmark for each task and identify where there is room to improve. We didn’t expect WorkfloPlus to prove to be such a useful training tool, and it’s given our workforce an unexpected but invaluable insight into their own strengths and weaknesses. It’s taken the guesswork out of how we support our staff,” said Miles.

Overall, the decision to digitise their work processes and harness the data this has provided has resulted in greater productivity and efficiency across the business and has made quality control faster and easier. Now, it takes just a few seconds to identify who assembled which cable, trace any issues, and understand what needs to be done to correct any problems.

Ultimately, WorkfloPlus has delivered the level of insight that Carrio had been searching for. According to Miles, “being able to see what is happening on the production floor hour by hour, day by day, has brought immense benefits in terms of productivity and insight into our own business.”

Initially the staff were hesitant to any changes to their existing approach, but quickly found using WorkfloPlus to have big benefits over the old paper-based processes.

Miles CarrioCEO Carrio Cabling

We didn't expect WorkfloPlus to prove to be such a useful training tool, and it's given our workforce an unexpected but invaluable insight into their own strengths and weaknesses.

Miles CarrioCEO Carrio Cabling