Manufacturing 2,400 chassis in 18 months, clear of defects and errors

MORryde International, based in Elkhart, Indiana, is a leading manufacturer of suspension systems and aftermarket products for the recreational vehicle (RV) and automotive industries. The company collaborates with OEM manufacturers to engineer innovative solutions that improve vehicle performance and durability.

With nearly 1,000 employees across 13 plants, MORryde has built a reputation for quality and innovation. However, a persistent torque control issue in its driveline assembly process threatened production efficiency and quality. To address this, the company turned to smart torque tools and a digital worker guidance system—unlocking major improvements in traceability, error-proofing, and process efficiency.

Challenges: Torque Control and Quality Issues in Automotive Assembly

Reinstalling driveshafts on modified suspension systems is a complex, multi-step process. When onboarding new technicians, MORryde identified a critical issue: inadequate torque control for fasteners, leading to potential defects.

Root Causes of the Quality Problem:

• Reliance on tribal knowledge – Technicians depended on hands-on experience rather than standardized work instructions.
• Paper-based work instructions – Printed travelers were outdated, inconsistent, and hard to follow.
• No real-time quality feedback – Errors were discovered after assembly, causing rework and inefficiencies.

Greg Whitt, Process Improvement Engineer, said, "Most of our work instructions have been hard copy travelers for a very long time. Our operations need to be better documented."

To improve fastener torque validation and eliminate defects, MORryde needed a smart manufacturing solution that provided real-time process control, digital work instructions, and automated error-proofing.

After implementing PICO, Whitt discovered that their assembly lines were gaining efficiencies from the new controls, measures, and instructions.

Solution: Smart Torque Tools and Digital Work Instructions

MORryde implemented digital worker instructions and connected the system to smart torque tools for its driveline assemblies.

How It Works:

1. Operator receives digital work instructions that highlight the correct fastener location.
2. Smart torque tool activates only when in the correct position, preventing incorrect tightening.
3. System validates the applied torque, ensuring precise fastener security.
4. All torque data is logged automatically, enabling 100% traceability.
5. Once complete, the system disables the torque tool, eliminating human error.

This worker guidance system ensures standardized assembly processes and real-time error-proofing, reducing defects and improving technician efficiency.

The software highlights which fastener is not properly torqued. Simple guidance like this makes error-proofing easy.

Results: Increased Output, Full Traceability, and Improved Efficiency

•  2,400 chassis produced defect-free – Eliminating fastener torque issues prevented quality failures.
• 500+ assembly processes migrated from paper to digital – Standardized instructions improved consistency.
• 50% increase in output for TV mount assembly – Worker guidance reduced rework and training time.
• 100% traceability for every fastener and work order – All process data is logged for audits and compliance.
• Seamless integration with ERP systems – Ensuring data continuity from production to supply chain.

Local TV station WBST-22 interviewed MORryde about their experience digitizing the shop floor. Watch the interview. 

Eliminating the fastener torque issue was a long-awaited win for Whitt. But, the biggest advantage is that their factory operations now have a baseline for improvement. Whitt said, "[Before PICO] we didn't have feedback loops for production rates. The only way to uncover the inaccuracies in our work plans would have been through labor-intensive time studies. Now, there's so much information from a time study standpoint and from having a feedback loop of how production is actually going on the floor.” 

Connecting smart torque tools with worker guidance resulted in immediate efficiency gains.  MORryde also shares that the ROI is fairly immediate. "PICO starts paying for itself right out of the box. There is an immediate value-add with automated data collection and worker guidance," said Whitt. One example he cited is the time for the technicians to refamiliarize themselves with a specific assembly process amongst many variations. As soon as the operator guidance was in place, MORryde recovered nearly all that non-value-added time.

What Other Automotive Manufacturers Can Learn From MORryde

MORryde’s success story highlights a growing trend in automotive manufacturing: the shift from manual, paper-based processes to smart, connected factory solutions.

• Faster technician training and onboarding
• Reduced defects and improved first-pass yield
• Real-time process monitoring and feedback
• Full production traceability and compliance

Whitt said, "We now ask the question, 'What else can we error-proof with Pico MES?'" That line of thinking has MORryde investigating alternative applications for Pico MES, such as quality control inspections and preventative maintenance.

Ready to digitize your manufacturing processes? Request a demo and see how PICO can help your factory achieve real-time traceability, error-proofing, and process automation.