CTG Helps thyssenkrupp Supply Chain Services Automate Work Instructions With Azure AI

The Challenge and Opportunity

thyssenkrupp Supply Chain Services provides supply chain management, warehousing, transportation, quality and value-added services across North America. With a large manufacturing ecosystem, consistency in inspection processes is critical for compliance with internal and external standards.

Over time, the organization identified a bottleneck in how work instructions (WIs) were created.  Inspectors were manually interpreting audit emails, defect images, and supporting quality data to build WIs aligned to a 14-step inspection lifecycle. This process was time consuming, subject to individual interpretation, and delayed responses when new quality issues emerged. The complexity stemmed from the volume and variety of information involved. Inputs came in unstructured formats such as images and emails, resulting in lost time, more manual effort, and greater variation in WI outputs. As the business scaled across regions and partners, the need for faster, more standardized WI generation became clear. Working with thyssenkrupp Supply Chain Services, CTG identified an opportunity to apply AI by automating the transformation of unstructured inputs into clear, compliant WIs while maintaining human oversight for validation.

The Solution and Results

The CTG team deployed an AI-enabled Proof of Concept (PoC) to automate WI generation, integrating directly with the client’s quality workflows. 
At the core is a pipeline that converts unstructured inputs into structured outputs aligned to the client’s 14-step WI framework, which spans the full inspection lifecycle, from receiving and unpacking through final audit and shipping.

The process works as follows:

• Supervisors upload defect images and audit inputs through a mobile application. 

• Azure OpenAI Vision analyzes images to identify defects and extract visual insights. 

• Azure AI Document Intelligence structures the extracted data, identifying elements such as part numbers, labels, and defect characteristics. 

• A domain-specific knowledge base applies the client’s language standards and inspection guidelines. 

• The system maps all extracted and enriched data into the appropriate WI sections.

• A structured draft WI is generated for review and approval before finalization. 

The solution is supported by an API that orchestrates workflows and ensures validation. Rather than replacing inspectors, the system is designed to accelerate their work. Each WI is delivered as an editable draft, allowing subject matter experts to review and refine outputs and maintain control over final approval.

The results of the PoC showed a positive operational impact:

• 50-70% reduction in manual effort required to create WIs 

• Improved consistency across WIs through standardized structure and language 

• Faster turnaround times for documenting and responding to quality issues 

• Scalability across multiple OEM formats and national operations

By combining Azure AI capabilities with manufacturing industry expertise, CTG helped thyssenkrupp Supply Chain Services establish a more efficient and standardized approach to WI creation. The PoC showed how AI can enhance productivity, support quality compliance, and enable teams to focus on higher-value inspection activities. 

This client story highlights how the right combination of expertise, strategy, and technology can create measurable business value. Explore the related solutions below to learn how CTG helps organizations solve complex challenges, improve performance, and accelerate transformation. When you're ready to discuss your challenges and goals, contact us to connect with an expert.