In the current iteration of Internet of Things (IoT), there are multiple hurdles to overcome. Where do we, as a company, start? How do we identify a proof of concept project for our next steps into digital applications? What type of ROI are we going to judge the project by after implementation? Clear Process Solutions has been an essential resource for companies in their quest to simplify complex processes, data and integrations. Here is a Quick Start Guide to identify opportunities and start digital process transformation in your organization:
- Create your team:This will be the team that will go through the plant and gather information about your processes and where they could be automated. A good template for the group is a person from quality, process engineering, and a plant supervisor or manager that the group can communicate honestly with as the leader for the project.
- Pick a Thursday or Friday post-morning-break to do a walk through: The reasoning behind this is to grab operations when they are operating at their standard level. All the operators are settled in, everyone has had their coffee and most importantly, you can view the operations with a fresh perspective.
- Document all paper and manual driven processes in the area chosen (take pictures): What documentation happens at the station? What does the company board look like? Is it up to date and easily understood by everyone? How often is it updated? Are your operators using paperwork instructions or relying on oral tradition? How is inspection being documented? How long does it take to gather this information outside of the process/cycle time? What happens to the information gathered? Is it handled a second time for entry into a system? What is the time frame before the data is entered? Is there a possible failure mode for data reentry?
- Meet the following week to review what was found: Set aside 1 hour to review what your individual findings were. A great place to start is where paper processes are being manually created or worked. Quantity complete, scrap quantity, time the job started, inspection reports, and scrap tags are all data that is applicable for automation. Are work instructions (WI) on paper? Is oral tradition the majority of knowledge on the floor? What drives the operator to continue to the next step in the process? Interactive digital work instructions give operators the knowledge and drives the process to completion.
- Determine 2-3 possible processes that would allow for easier floor operations: This can be as simple as making your prints and work instructions digitally interactive. Creating digital machine maintenance forms, including sign-offs, removes the missed sign-off sheets that auditors love to find. If any data is being manually entered into your ERP, MES or other lines of business from the shop floor, that data is being twice handled and inefficient. Not to mention it opens up a failure mode that could cost you and your customer.
- Contact Clear Process Solutions to assist in the next steps of your company’s digital process transformation:
CPS offers a group of low-code/no-code options, that enable your company to capture the data in ways that work for you, without having to go through long timetable structure changes. We also future proof the systems put in place so when your company grows and adopts new systems, CPS is right there with you to ensure the next growth is an adventure, not a pain.