IMEG was hired by a marking and coding equipment manufacturer to develop digital Work Instructions and implement Visual Knowledge Share (VKS), a work instruction software.
THE PROBLEM
Paper based work instructions (WIs) in a digital world. Reliant on printed PDFs in bulky binders.
Text-heavy WIs that did not allow clean visualization of work to be performed.
Outdated WIs that were difficult to update and maintain due to their printed nature.
Operators had no incentive to read through and follow printed work instructions for daily work, leading to operators relying on memory and deviating from set procedures over time.
With an influx of new hires, experienced personnel were trapped in training activities.
Inability to collect and compile operational data like:
Inspection records
Cycle time
Process yields
Waste
THE PLAN
Develop digital work instructions that will be delivered to operators using a cost-effective solution like Visual Knowledge Share (VKS), a work instruction software.
Conduct on-site observations in collaboration with experienced operators to collect pictures, videos and key insights about the processes.
Digitize the workspace by sourcing and installing effective hardware at workstations.
Set up, test and utilize multiple VKS functions that enable better process control like:
Collect cycle data for: Serialized part usages, inspection records, quantity produced, and more
Non-conformance Reporting and Resolution
Workorder and productivity tracking
Design and set up WI review and approval flows within VKS that are key for managing future changes and version releases.
Introduce and train operators, team leaders, supervisors and process engineers to VKS to ensure a good transfer of ownership and control.
THE RESULTS
Developed 80+ digital work instructions in VKS (also known as guidebooks).
Assisted in the set up of 15+ workstations to enable utilization of VKS on the production floor.
Operators, supervisors and process engineers now have access to picture & video based, stepwise work instructions that are:
Guided by annotations and appropriately timed prompts
Collecting cycle data like serialized part usage, inspection and non-conformance records, etc.
Easy to use as training resources for new hires
Inculcating desirable work habits that minimize the risk of process deviations
