{"id":9837,"date":"2021-03-09T16:40:14","date_gmt":"2021-03-09T15:40:14","guid":{"rendered":"https:\/\/ezfactory.nl\/?p=9837"},"modified":"2024-11-08T14:13:25","modified_gmt":"2024-11-08T13:13:25","slug":"continuous-improvement","status":"publish","type":"post","link":"https:\/\/ezfactory.nl\/en\/knowledge-base\/continuous-improvement\/","title":{"rendered":"Continuous Improvement"},"content":{"rendered":"<p><strong>Jungle Power Drinks* implemented EZ-GO a year ago and the app has become an integral part of the job. Plus, the team discusses the data from the platform in their weekly team meetings, in order to keep improving continuously. We will be joining one of those meetings, where Youssef is introduced as a new operator and Bianca gives her colleagues a firm scolding.<\/strong><\/p>\n<p>It is Tuesday morning 07.20 AM as the day shift operators stroll into the meeting room. There are large glass windows that offer a full view of the production floor. At precisely 07.30 AM, twelve operators sit at the table and team leader John Veldman kicks off the meeting.<\/p>\n<p>\u2018Good morning all, and a special welcome to Youssef, our new operator on the packaging line. He will be joining Bianca for the day.\u2019<\/p>\n<p>Everyone looks at the fashionably dressed young man with large brown eyes.<\/p>\n<p>Bianca says: \u2018I&#8217;m sure we\u2019ll get along very well, Youssef\u2019.<\/p>\n<p>John shakes his head: \u2018Well, that\u2019s good to know. Since we aren\u2019t here just for the coffee, let\u2019s get to it.\u2019<\/p>\n<p>The main topics appear on the centre screen. The team knows them back to front by now:<\/p>\n<ul>\n<li>Hazardous situations<\/li>\n<li>AM statistics<\/li>\n<li>Improvements<\/li>\n<li>Announcements and questions<\/li>\n<\/ul>\n<h2>Hazardous floor<\/h2>\n<p>John: \u2018A potentially hazardous situation was reported this week by our production leader, Robin. As he was passing the filling machine, he noticed that the floor was slippery. Can you guess how that happened?\u2019<\/p>\n<p>No response and eleven blank stares. Bianca\u2019s gaze scans the group, lips pressed together tightly.<\/p>\n<p>John proceeds to display the statistics of the relevant task on screen. Sure enough, the task hasn\u2019t been signed off 7 times in the past months.<\/p>\n<p>Bianca can\u2019t hold it in any longer and explodes: \u2018What do I keep telling you people? That floor needs to be swept and mopped at the end of the night shift on Wednesdays and we&#8217;re just not doing it! It doesn\u2019t take a genius to figure that out! Is it because I&#8217;m a woman, that I&#8217;m the only one around here who seems to understand the importance of cleaning?\u2019<\/p>\n<p>Youssef bursts into laughter.<\/p>\n<p>Meanwhile, John displays the list of scheduled and executed tasks in EZ-GO on screen.<\/p>\n<p>\u2018I think there\u2019s a different culprit, Bianca.\u2019<\/p>\n<p>Everyone stares at the screen, that shows an overview they haven\u2019t seen before. Each cluster of final tasks per shift has a number of minutes, varying from 8 to 36 minutes per cluster.<\/p>\n<p>John clarifies: \u2018You can enter the scheduled time frame per task into the EZ-GO platform. I started doing that, and got some very enlightening results. For example, this shows that the week closure of the night shift on Wednesdays takes 36 minutes. That is much more than our schedule accounts for.\u2019<\/p>\n<p>A buzz emerges around the table. Everyone is checking their own shifts and those before and after theirs to figure out what\u2019s going on.<\/p>\n<p>\u2018See\u2019, Bianca exclaims, \u2018my closure on Fridays is packed too tightly. While on Thursdays, I\u2019ve always got time to spare.<\/p>\n<p>The team agrees to review the task list at another time and spread certain tasks more evenly throughout the week.<\/p>\n<p>Another operator asks: \u2018Could we take a look at tasks that are being over-scheduled as well?\u2019 \u2018I find myself inspecting the same squeaky-clean sensor every day. A weekly inspection would do just fine.\u2019<\/p>\n<p>John: \u2018Good suggestion. Let\u2019s discuss those as well.<\/p>\n<h2>Prevention beats resolution<\/h2>\n<p>\u2018OK people, let\u2019s move on\u2019, John says as he watches the minutes tick away. \u2018Let&#8217;s take a look at maintenance task deviations.\u2019<\/p>\n<p>Almost all tasks are marked green, which means they are being executed 100% every time. Except one: the box puller.<\/p>\n<p>Youssef chuckles. \u2018Is that the official name?\u2019<\/p>\n<p>\u2018Yes, Youssef, that\u2019s the official name\u2019, Bianca responds. \u2018It&#8217;s a machine that uses suction cups to pull packaging boxes into the right shape. Those suction cups need to be inspected twice a week. Wear them out or get them dirty, and they will malfunction.\u2019 She looks around the table. \u2018And we don&#8217;t want that now, do we?\u2019 Her colleagues nod. Nobody would dare to go against Bianca anyway, but she is right.<\/p>\n<p>John proceeds: \u2018If you all agree that this is so important, then why has this task been skipped two weeks in a row now? Of course, I can see by whom, but that\u2019s not the point right now. You all service that machine every now and then. Why isn\u2019t this being done as scheduled?\u2019<\/p>\n<p>One of the operators takes the floor. &#8216;It really takes a lot of time, because you need to get deep inside the machine to get to those suction cups, and you have to shut down the whole machine for at least 20 minutes to do the inspection and cleaning. On some days, there simply isn\u2019t enough time. We can\u2019t keep cutting the production process like that.\u2019<\/p>\n<p>Bianca responds: \u2018But last week we had to stop production for two hours because of a malfunctioning cup. Isn\u2019t that much worse?\u2019 She looks at Youssef, who is happy to be involved this soon: \u2018Uhm, yes, 40 minutes a week is not as bad as a 2-hour interruption. And interruptions never come at a good time.\u2019<\/p>\n<p>\u2018Exactly!\u2019 Bianca wants to slap his back, but restrains herself. She doesn\u2019t want to intimidate the kid too much. \u2018We had an express order which we failed to make in time. The client was extremely pissed off.\u2019<\/p>\n<p>John looks around the table. \u2018That\u2019s right, it cost a lot of time and money. Listen, I understand you want to get on with production and I appreciate your commitment, but we really cannot be skipping these inspections. It is a necessary step, so please do turn off that machine for 20 minutes.\u2019<\/p>\n<h2>Solved!<\/h2>\n<p>The next agenda item: improvement reports. Once the EZ-GO app had been implemented last year, the first few weeks were riddled with reports of loose screws, illogical practices, polluting situations, etc. Those issues were all solved in the first few months, which immediately caused a considerable drop in short outages and malfunctions, while eliminating a number of hazardous situations and improving the work environment. According to John, there is no doubt that this has caused the entire productivity increase of 10% in the same period.<\/p>\n<p>And today, operators still enter several reports a week into the app; imagery, proposed solutions and all. This week, they are discussing a report by Wolf. \u2018I had that name \u2018before it was popular\u2019, The bearded fifty four-year-old operator tells Youssef before they begin.<\/p>\n<p>The others sigh. He says that to every single new person he meets. Wolf proceeds undisturbed: \u2018So, it\u2019s about those flasks that kept falling over on line 4. This was causing a lot of short interruptions and as it turns out, that was the result of a sensor that kept getting knocked out of position by the machine\u2019s own vibrations. In deliberation with Maintenance, we decided to enter an extra inspection task into the app, to check the sensor and fix its position if necessary. So, now you know why that task is there.\u2019<\/p>\n<p>John asks: \u2018But there was more, right?\u2019<\/p>\n<p>\u2018Yes, that\u2019s the best part\u2019, Wolf proceeds. \u2018We won\u2019t be needing that extra action for long because Maintenance has ordered a new sensor bracket. It will arrive in 2 weeks. Once replaced, we will remove the task from the list.\u2019<\/p>\n<p>Youssef: \u2018Amazing. So you\u2019ve basically got a temporary fix and a real solution.\u2019<\/p>\n<p>\u2018Exactly\u2019, Wolf responds. \u2018And you\u2019d still get it right even if you had missed this meeting, because those tasks will pop up in the app automatically. And disappear the second they are no longer needed.<\/p>\n<p>\u2018Cool.\u2019<\/p>\n<h2>Training<\/h2>\n<p>John has a final announcement to make before he concludes the meeting just in time.<\/p>\n<p>\u2018Ladies and gentlemen, I&#8217;ve got some good news. You&#8217;ve all met our new colleague Youssef, but as of next week we will be joined by 6 more operators, 2 for every shift.\u2019<\/p>\n<p>A buzz emerges and Wolf decides to speak up: \u2018That\u2019s nice, boss, but how exactly are we going to train them all at the same time? And how do we know where to deploy them? We don\u2019t know what someone can and can\u2019t do.\u2019<\/p>\n<p>John smiles. \u2018Bianca will be training Youssef with the app today, and that&#8217;s exactly how we\u2019re going to do it with the others.\u00a0 It will hardly cost her any extra time, and Youssef will be able to start using the app himself within a day.\u00a0 But there\u2019s something else I\u2019d like to show you.\u2019 An audit in the app appears on screen, titled, \u2018skills\u2019. \u2018This audit allows you to indicate that someone has been trained on a certain task and to what extent they have mastered it. So, we all know whether someone has been trained or not, and where to deploy them.\u2019<\/p>\n<p>\u2018And we can do all of that in the app?\u2019<\/p>\n<p>\u2018It\u2019s not just an app, Wolf, it\u2019s a combination of an app with a platform underneath. Everything we\u2019ve discussed today, is based on data from the platform. It helps us improve continuously while making our jobs safer, more efficient and more fun.\u2019<\/p>\n<p>Bianca jokes: \u2018Don\u2019t exaggerate, John\u2019. \u2018Now you\u2019re just showing off for our new colleague.\u2019<\/p>\n<p>John blushes. She&#8217;s got that exactly right.<\/p>\n<p>&nbsp;<\/p>\n<p><em>*Jungle Power Drinks is a fictitious organisation. Read the previous stories about this fast-growing company here. <\/em><\/p>\n<p>&nbsp;<\/p>\n<p><em>This is part of a serial about the fictitious company Jungle Power Drinks. By describing their experiences with AO and the EZ-GO app, we demonstrate the possibilities to improve the safety, quality and productivity of the operation. Read part <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/increase-safety-efficiency-and-job-satisfaction-with-autonomous-maintenance\/\"><em>one<\/em><\/a><em>, <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/autonomous-maintenance-getting-off-to-a-flying-start\/\"><em>two<\/em><\/a><em>, <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/autonomous-maintenance-your-machines-are-now-safe-clean-and-reliable-how-do-you-keep-them-that-way\/\"><em>three<\/em><\/a><em>, <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/the-operations-director-is-visiting-for-an-inspection-no-problem\/\"><em>four<\/em><\/a><em>, <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/the-operations-director-and-the-secret-of-the-30-productivity-increase\/\"><em>five<\/em><\/a><em>, <\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/meeting-exploding-demand-easy\/\"><em>six<\/em><\/a>,<em>\u00a0<\/em><a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/the-happy-operator\/\"><em>seven<\/em><\/a><em> and <a href=\"https:\/\/ezfactory.nl\/en\/knowledge-base\/critical-questions-what-is-the-added-value-of-the-ez-go-app\/\" target=\"_blank\" rel=\"noopener\">eight<\/a> here. <\/em><\/p>\n<p>&nbsp;<\/p>\n<p><em>Randy Appiah<\/em><\/p>\n<p><em>Robert Bouwman<\/em><\/p>\n<p><em>EZ Factory founders<\/em><\/p>\n<p>&nbsp;<\/p>\n<p>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: <a href=\"https:\/\/www.pontifexx.nl\/\" target=\"_blank\" rel=\"noopener noreferrer\">https:\/\/www.pontifexx.nl\/<\/a>.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-medium wp-image-3574 aligncenter lazyload\" src=\"data:image\/gif;base64,R0lGODlhAQABAAAAACH5BAEKAAEALAAAAAABAAEAAAICTAEAOw==\" data-src=\"https:\/\/ezfactory.nl\/wp-content\/uploads\/2020\/04\/p2_50-300x96.png\" alt=\"Pontifexx Autonomous Maintenance Continuous Improvement\" width=\"300\" height=\"96\" data-sizes=\"auto\" data-srcset=\"https:\/\/i0.wp.com\/ezfactory.nl\/wp-content\/uploads\/2020\/04\/p2_50.png?resize=300%2C96&amp;ssl=1 300w, https:\/\/i0.wp.com\/ezfactory.nl\/wp-content\/uploads\/2020\/04\/p2_50.png?resize=20%2C6&amp;ssl=1 20w, https:\/\/i0.wp.com\/ezfactory.nl\/wp-content\/uploads\/2020\/04\/p2_50.png?resize=190%2C61&amp;ssl=1 190w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Jungle Power Drinks* implemented EZ-GO a year ago and the app has become an integral part of the job. Plus, the team discusses the data from the platform in their weekly team meetings, in order to keep improving continuously. We will be joining one of those meetings, where Youssef is introduced as a new operator&hellip;<\/p>\n","protected":false},"author":19,"featured_media":9842,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[174,100],"tags":[],"class_list":["post-9837","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-knowledge-base-en","category-news"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Continuous Improvement - EZ Factory<\/title>\n<meta name=\"description\" content=\"Digitize your factory checklists, core tasks, audits and work instructions. 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