In the manufacturing world, most want to improve and sustain their Overall Equipment Effectiveness (OEE), which is the multiplication of Availability x Performance x Quality. The actions of the workforce can have a significant impact on all three components, especially Performance and Quality, but also Availability. To that end, many are now considering the impact and benefits of guided workflow for Control Room Operators and Field Operations, where the connected worker comes into play. Guided workflow is all about taking Standard Operating Procedures (SOP’s) and transitioning them to electronic work instructions. The Digital SOP is an electronic work instruction that functions as an enabler for more consistent results while also providing much greater awareness of the status of work in progress (WIP). And yes, the Digital SOP also provides traceability about who, when, and how long it took to complete a task.
Manufacturing Execution Systems (MES) like TrakSYS are real-time systems that connect, monitor and control workflow and data flow on the plant floor to optimize management of operations from the warehouse to the shipping dock (dock-to-dock) inclusive of quality management, material management, planning/scheduling, and performance monitoring. The main goal of MES is to ensure efficient and effective execution of manufacturing operations and improve production results.
So why is TrakSYS a good fit for digitalizing SOP’s? It is because it is designed to automate simple linear workflow as illustrated in the first diagram below while also providing proper tools to automate more complex workflows as illustrated in the second diagram.
Simple, Linear Workflow
More Complex Workflow
The process of laying out an MES workflow solution can simply start with existing SOP’s but can also start with procedures and functions diagrammed on paper or a white board by both business and technical team members. These visual diagrams can then become components of the functional requirements for implementation. TrakSYS implementation tools closely mimic traditional workflow diagrams, making it easy to transfer concepts from SOP and paper/whiteboard into a digital solution. When digitalizing the workflow in TrakSYS, all necessary workflow functions are accessible including waiting, execution, transitions, splitting, merging, etc.
As workflow processes are executed, visualization is provided using standard Content Parts and Pages. These live diagrams allow users and management to monitor simple and complex workflows and quickly determine status, as well as any issues that may be occurring.
Overview Displays Highlighting Real-time Status and Open Tasks
TrakSYS allows you to present workflow in various visual formats that are best suited for the specific tasks and different personas (Operations, Quality, Maintenance, Planners, etc.). Once the activity has been selected, the work instruction can be displayed as a simple checklist or can transition the user from step to step, presenting relevant information in context at each step.
Workflow Initiated
Work Instructions as Simple Checklist
Work Instructions to Guide the User
This can all be deployed and maintained in a modular fashion. Process changes become easy to plan, implement, and test, allowing the solution to evolve with the business. As your teams (and business needs) evolve and change, the modular environment enables new team members to learn, contribute to, and care for your TrakSYS solution. In short, the visual nature of the workflow configuration and monitoring encourages the evolution and improvement of business processes.
MES workflows have been designed, of course, to function on mobile devices of all kinds. TrakSYS is “responsive” by nature, meaning the application will re-size based on the available screen size of the mobile device being used. A variety of information can be presented to the user based on the specific application.
Connected Worker – Mobile Work Instructions Due and Status of Work in Progress
So why make the investment in TrakSYS MES now? Is the time right for you? The Digital SOP will inherently lead to team members making fewer mistakes, which in turn will result in improved, sustainable OEE along with a safer workplace. It will also make it much easier to manage turnover in your workforce.
With electronic work instructions in place, new team members can be productive much more quickly. Yes, it will take months or years for them to become the Process Managers you need them to be, but in the meantime, they will not be creating deviations that will not only increase your manufacturing costs but could also harm your customers and damage your brand.
Jon Hall
Vice President, Digital Transformation
Adatafy™
All images herein represent actual visuals or artistic representations from Parsec Automation’s TrakSYS™ MES Platform.
