lean manufacturing

CASE STUDY: Wire Harness Manufacturer Increases Productivity 50% with ShiftWorx

June 12, 2024 | FreePoint Technologies Inc.

About the Client


Excel Connection is an industry leader in manufacturing cable assemblies, wire harnesses, lead wires, ribbon cables, coaxial cables, fiber optics, power cables, heavy gauge and electro-mechanical assemblies.

The Challenge


As many manufacturers do, Excel Connection faces the challenge of frequent set-ups for multiple customers with many different products. Prior to implementing ShiftWorx shopfloor management software, some jobs required up to an hour of preparation before the machines could be productive.

Operators spent time finding wiring and other materials that were placed in hard to reach areas, helping others, waiting for a lead hand to set up, or waiting for instructions. In other words, people were usually busy, but not always productive.

The Solution

After implementing ShiftWorx, Excel Connection experienced a significant decrease in machine downtime which considerably increased their capacity on critical processing machines, as well as improved employee engagement overall.


“It really made a difference when people saw how their machine was running and knew their co-workers could see that too.”
~Business Manager


With real-time data providing deeper process insights, Excel Connection was able to identify bottlenecks in their process that was contributing to unplanned downtime. Less time was spent unproductively, and more time was spent on production. Productivity for their critical cutting machines increased 40%, and on their bottleneck process, it increased 60%.productivity

Having production data visualized in front of them, employees became more efficient and productive. The live dashboards on display created a more engaging, gamified and competitive culture on the shop floor, encouraging operators to keep their machine running, with bonuses offered as a further incentive for top performers.

Overall, Excel Connection managed to reclaim hours of lost daily production time, which in turn increased their overall production capacity by 50%. With ShiftWorx’s Downtime Narration module, Excel Connection generates downtime reports to analyze their data and see what other impactful process changes they can make in the future!

The Outcome

  • Improved Employee Engagement and Corporate Culture.
  • Significant Reduction in Machine Downtime.
  • 50% Increase in Production Capacity.


Improved Employee Engagement

Team work to reduce machine downtime increased the capacity on critical processing machines and boosted employee engagement overall.

Significantly Reduced Downtime

Critical cutting machines productivity increased 40% and bottleneck processes productivity increased 60%.

Significantly Increased Productivity

Real-time data provided deeper process insights which identified bottlenecks in production leading to 50% increased productivity overall!


When implementing a shopfloor management solution, choose a technology partner who understands lean and Toyota’s manufacturing methodologies – ShiftWorx software by FreePoint Technologies provides a ‘holistic’ shopfloor management platform that features a fully-modular suite of products including production scheduling, standardized work instructions, digital andon and manufacturing notifications – modules that when applied in whole or in succession afford manufacturers a production optimization solution backed by Toyota Production System (TPS) consulting expertise.

Don’t hesitate to contact us today for a complimentary consultation and demo specific to your Industry or shopfloor requirements!

Learn More About the Full-Suite of ShiftWorx Products!


ShiftWorx Software

It all starts with getting your shop floor assets cloud-connected; featuring patented data extraction and visualization technology, ShiftWorx impacts continuous improvement actions instantly with smarter decisions, faster! Book a demo today.


Standardized Work Instructions

Standardized work instructions provide full-accountability in work instructions delivery, whether it’s preventive maintenance, assembly instructions, quality control or more, traceability reduces errors. Book a demo to learn more!


Digital Andon System

Digital Andon improves shop floor communication and production uptime by ensuring operational or quality issues are addressed quickly! Wireless and easy to integrate – expedite the resolution of production and quality problems today.


Production Scheduling Software

Spreadsheet or paper-based job schedules are difficult to manage, maintain, distribute, and access, which is costing you money. Maximize operational throughput with production scheduling software.