{"id":4874,"date":"2020-09-22T15:17:46","date_gmt":"2020-09-22T14:17:46","guid":{"rendered":"https:\/\/ezfactory.nl\/?p=4874"},"modified":"2024-12-24T14:10:58","modified_gmt":"2024-12-24T13:10:58","slug":"the-happy-operator","status":"publish","type":"post","link":"https:\/\/ezfactory.nl\/en\/knowledge-base\/the-happy-operator\/","title":{"rendered":"The happy operator"},"content":{"rendered":"

Wolfgang works for a fictional German soda producer called Jungle Power as their Projektmanager Digitalisierung Betrieblichen Prozessen<\/em>. He is visiting the Netherlands to get to know the digital operator app EZ-GO. He isn\u2019t quite convinced of the benefits but a meeting with operator Bianca, a tough lady who doesn\u2019t mince words, is about to change everything. <\/strong><\/p>\n

Two weeks earlier, Wolfgang had a long call with John Veldman, a team leader at the Dutch factory that produces the healthy drink Jungle Power and an enthusiastic user of the app. John kept going on about the app\u2019s major benefits, but Wolfgang is a prudent man who doesn\u2019t believe anything at face value, especially over the phone. Today, he will tour the factory in Veghel and intends to take a critical approach. His approval of this app means it will be implemented in all sixty Jungle Power factories all over the world \u2013 not a decision to be made lightly and there\u2019s no room for mistakes.<\/p>\n

Smooth processes<\/h2>\n

John bids him a warm welcome and surprises him with a good cup of coffee and cake (those Dutchies are starting to learn). Then they climb a flight of stairs to the observation deck with a full view of the entire factory. Wolfgang has to admit it looks very well organised. But the same goes for their main location in Germany and they didn\u2019t need an app to achieve that.<\/p>\n

John Veldman pulls off quite a decent level of German as he vividly describes the implementation process. And yet, Wolfgang is finding it difficult to listen as he keeps getting distracted by the operation in front of him. All those people are constantly moving around but never seem to be in a hurry. It\u2019s a smooth process, almost like a dance. He shakes his head and sets himself straight. You aren\u2019t here to get all poetic, Wolfgang. You aren\u2019t Goethe, keep it formal.<\/p>\n

To the floor<\/h2>\n

Wolfgang interrupts John in the middle of a sentence about the tonnes of paper they have been saving. \u2018Can\u2019t we just head out to the floor?\u2019, he asks.<\/p>\n

John lights up. \u2018It would be my pleasure.\u2019<\/p>\n

\u2018I want to talk to an operator. The source, so to speak.\u2019<\/p>\n

\u2018Not a problem, all we need is some protective clothing.\u2019<\/p>\n

Back in the dressing room, John taps a screen. A video appears, demonstrating step by step where to find the overalls, hairnets and shoe covers and how to put them on.<\/p>\n

\u2018Is that ehm\u2026\u2019 Wolfgang stumbles.<\/p>\n

\u2018EZ-GO, yes, now that you mention it.\u2019<\/p>\n

Once they arrive at the factory floor, Wolfgang first observes the operators from a distance. He is looking for the most serious face around to have a chat with. \u2018That lady over there, with the tight ponytail. At the packaging line.\u2019<\/p>\n

\u2018Bianca\u2019, John responds, \u2018one of our best operators. Are you sure?\u2019<\/p>\n

\u2018Why do you ask?\u2019<\/p>\n

\u2018She takes her job very seriously and doesn\u2019t like to be interrupted.\u2019<\/p>\n

\u2018That is very commendable. Please introduce us.\u2019<\/p>\n

Bianca<\/h2>\n

Bianca barely looks up from her work as she gives some curt answers to Wolfgang\u2019s questions. How long has she been working here? Fourteen years. Is she pleased about the app? Yes. How has it improved her work? She stops for a moment and gives Wolfgang a stern look with her piercing green eyes as she reaches for an iPad. \u2018Why don\u2019t you just see for yourself, sir. It will save me time and answer all your questions.\u2019<\/p>\n

Although she said it in Dutch, he gets the gist and it doesn\u2019t even occur to him to object. And so, he begins to observe.<\/p>\n

\u2018You\u2019re lucky, sir. This is the weekly cleaning and inspection round. It consists of ten inspections to make sure my line is and remains in peak condition for the weekend. After all, we don\u2019t want any problems when the weekend shift begins, right?\u2019<\/p>\n

\u2018No, certainly not\u2019, Wolfgang quickly concedes.<\/p>\n

She demonstrates the EZ-GO app on an iPad and taps the Checklist<\/em> End of Week Cleaning & Inspection<\/em> icon. A checklist appears and she opens the first item: Cleaning 3 sensors packing machine<\/em>.<\/p>\n

‘In English?’ Wolfgang asks.<\/p>\n

She looks up. \u2018You don\u2019t think I speak English? We\u2019ve got people working here from Eastern Europe, Spain, Somalia, and so on. They should probably understand it too, don\u2019t you think?\u2019<\/p>\n

\u2018Ja nat\u00fcrlich, Frau Bianca.\u2019 he finds himself saying in his own language.<\/p>\n

Check, improve, prevent<\/h2>\n

A series of photos appears on-screen: three sensors and how to brush them clean. In a matter of seconds, Bianca routinely performs the task and presses the thumbs up button on the screen. \u2018Done. Want to see more or can I get on with it?\u2019<\/p>\n

\u2018I\u2019d like to see more.\u2019<\/p>\n

Her finger hovers over the next item on the list: Remove glue residue<\/em>. A smile appears on her face for the first time. \u2018This one is fun\u2019, she says. \u2018A lot of fun. We had issues with this boxing machine for years. The conveyor belt rollers kept accumulating glue and the machine kept deteriorating as a result. Until one time, we had to halt operations for five hours because the conveyor belt had ripped. Five hours! That\u2019s a lot of boxes! No spare belt in stock, waiting for a new belt to arrive \u2013 you know the drill.\u2019<\/p>\n

He doesn\u2019t, but nods in agreement.<\/p>\n

\u2018Anyway, once the problem was fixed, we put up a note on the machine: Remove glue residue after each shift. <\/em>Guess what?\u2019 She doesn\u2019t await the answer. \u2018I was the only one who would follow the instruction. Sometimes. Anyway, six months down the line, another broken belt, spare belt not in stock once again, expedited order \u2013 another shift worth of boxes lost. Made a new print of the note, with more colours and exclamation marks. But as you\u2019ve probably guessed by now\u2026\u2019<\/p>\n

\u2018You were the only one who would follow the instruction.\u2019<\/p>\n

She nods. \u2018Then John showed up with his app. I remember thinking \u2018what\u2019s the point, I\u2019m not tech savvy and all we need to do is clean things, what\u2019s so complicated about that?\u2019 But John didn\u2019t take no for an answer and I\u2019m glad he didn\u2019t. Sorry for the lengthy introduction, let me show you.\u2019 She taps the item Remove glue residue<\/em>. A video appears, less than ten seconds long, demonstrating how to remove glue residue at the bottom of the belt to prevent it from accumulating. Bianca performs the task, ticks the box and turns to Wolfgang.<\/p>\n

\u2018Is that it?\u2019, he regrets asking.<\/p>\n

Bianca is not amused.<\/p>\n

\u2018\u2019Is that it\u2019? This saves us several production days a year! Plus, the machine runs better. And all it takes is a two-second task. In the first version of the app, this was still marked as a daily task. But because everyone was actually doing it, the machine didn\u2019t get dirty anymore and we were able to bring it down to twice a week. Then, I thought the type of glue might play a role, which I reported in the app. Look, here\u2019s how you do it.\u2019 She points at a button that says report action<\/em>. \u2018As it turns out, a better type of glue had come out, so now we only need to do it once a week, see?\u2019 Wolfgang hears it loud and clear. As he begins to calculate how much this will save the company, a loud bell interrupts his thoughts. \u2018Coffee!\u2019, Bianca concludes. \u2018I\u2019ll just wrap up these checks, if you don\u2019t mind.\u2019 As Wolfgang glances to the side, he realises that John has been standing there all along. John smiles: \u2018Now do you see why I asked you to come take a look for yourself, Mr. Sandburg? The workforce truly got behind the idea, there is little for us to do in that regard.\u2019 Mr. Sandburg nods. \u2018Call me Wolfgang.\u2019<\/p>\n

Happiness is in an empty bin<\/h2>\n

\u2018Thank you very much, Frau Bianca,\u2019, Wolfgang says. You were right, this does answer all my questions.\u2019<\/p>\n

\u2018Not at all\u2019, she says as she calmly proceeds with her final checks. \u2018You haven\u2019t got a clue. See that waste bin over there, with the film waste?\u2019 She points at a bright yellow container. \u2018It used to be full and surrounded by film laying around the floor all the time. I believe someone from your office once even tripped over it. Today, it is a task in the EZ-GO app, to be performed at the start of each shift. The glue reservoir; used to be empty at the start of my shift. Now the app prompts it as a task at the end of each shift, allowing the next shift to get started right away. See that old computer collecting dust over there? That is where we used to get our first line maintenance tasks and checklists: search for the right one for your shift, try to memorise it, print it out just in case, perform the tasks and checks, back to the computer, tick all the boxes, save. And if you wanted to report anything, you had to create an action item and submit it by email, upload a photo \u2013 way too cumbersome to bother.\u2019<\/p>\n

Onboarding is easy as pie<\/h2>\n

\u2018The worst part of it all\u2026\u2019 she says as she briefly makes eye contact. \u2018\u2026onboarding someone new. Those instructions were organised in folders in a drawer underneath the computer and they were always, and I mean always, outdated. So, the person responsible for training a new colleague was screwed. They had to sit there and update work instructions. Oh, the sheer time I\u2019ve wasted! And new staff would keep making mistakes because there is no way they were able to remember all of it. Since the app, I show them the ropes once and the second time around they are comfortable doing it all on their own, with the app. Pretty EZ, if you ask me.\u2019 She laughs at her own pun.<\/p>\n

Wolfgang is lost for words. This is as water-tight as can be. Bianca puts away the iPad, brings her face real close to Wolfgang\u2019s, winks and says: \u2018Truly, sir, even you\u2019d be able to do it.\u2019 She turns around and decisively walks into the canteen without looking back.<\/p>\n

\u00a0<\/em><\/p>\n

This is part seven of a column about the fictional company Jungle Power Drinks. By describing their experiences with AO and the EZ-GO app, we demonstrate the possibilities when it comes to improving the safety, quality and productivity of the operation. In case you missed it, here are parts <\/em>one<\/em><\/a>, <\/em>two<\/em><\/a>, <\/em>three<\/em><\/a>, <\/em>four<\/em><\/a>, <\/em>five<\/em><\/a> and <\/em>six<\/em><\/a>. <\/em><\/p>\n

 <\/p>\n

Randy Appiah<\/em><\/p>\n

Robert Bouwman<\/em><\/p>\n

EZ Factory founders<\/em><\/p>\n

 <\/p>\n

If you want more information on how to implement Autonomous Maintenance within your factory, or take it to the next level: our partner Pontifexx can help you. Visit their website for more information: https:\/\/www.pontifexx.nl\/<\/a>.<\/p>\n

\"Pontifexx<\/p>\n","protected":false},"excerpt":{"rendered":"

Wolfgang works for a fictional German soda producer called Jungle Power as their Projektmanager Digitalisierung Betrieblichen Prozessen. He is visiting the Netherlands to get to know the digital operator app EZ-GO. He isn\u2019t quite convinced of the benefits but a meeting with operator Bianca, a tough lady who doesn\u2019t mince words, is about to change…<\/p>\n","protected":false},"author":19,"featured_media":4883,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[100],"tags":[],"class_list":["post-4874","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news"],"yoast_head":"\nThe happy operator - EZ Factory<\/title>\n<meta name=\"description\" content=\"The happy operator. 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