We’ve laid out a vision of the CPG Factory of the Future that will help you determine your next steps.
With Industry 4.0 in full swing, most companies are plotting their path right now to their own factory of the future as technologies like 3D printing, 5G, RFID, blockchain, robotics, and industrial mobile have become practical to deploy.
The question most companies are wrestling with is – what is the optimal mix of technology and human involvement? We’ve laid out a vision of a factory of the future that may help you determine your next steps. (Download our “The CPG Factory of the Future Isn’t What You Expect” eBook)
To make this all work, we believe humans need to be at the center of your operations and we offer a practical approach to bring industrial-grade software to the shop floor via mobile to execute, measure, and continuously improve work.
While there is a lot to consider, we believe there is really just one logical place to start. Machines are now incredibly reliable. The meantime between failure is now 20x higher than it was in the 1960s and the gains have now plateaued. This leaves human actions associated with availability, productivity, quality, waste, and safety as the remaining efforts to perfect in your operational system. These are traditionally the levers of Overall Equipment Effectiveness (OEE). (Download our “3 Reasons Why Humans Should Be at the Center of OEE” Executive Brief)
As tastes change and relatively more affluent consumers demand more options, companies are trying to get their plants to do more. This pressure to reconfigure on the fly is the source of most error. Quality guru W. Edwards Deming pointed out that 94 percent of all errors come from the system, with only 6 percent caused by humans directly. By system, he meant what we ask people to do and the organization of the instructions and tools we give them to do the work. The problem is, therefore, actually our management of even more complex industrial environments. (View our “Blueprint for the Factory of the Future” Infographic)
To tame these new complex systems, we need to be able to roll out processes quickly. At Parsable, we’ve built a Connected Worker Platform to make this exceedingly easy, allowing companies to roll out new processes at will, whenever an improvement or issue is identified. (Download our “5 Forces Driving the Rise of Connected Worker Applications in Operational Technology” Executive Brief)
For CPG and industrial manufacturers, we now offer a new approach to OEE that we call OEE 2.0. What we’ve done is embrace that variability comes from the system as people execute. We have isolated the processes humans impact the most, focusing first on the availability of the whole factory or uptime. These include changeovers, maintenance, and safety. We have created specific accelerators that include pre-built processes, pre-built data pipelines
Parsable already offers a Connected Worker Platform that
OEE 2.0 for Connected Workers is a collection of Accelerators that run on Parsable’s Connected Worker Platform to help companies make giant strides in OEE performance in just weeks.
Why: We saw that much of the industry still struggles with OEE and considers it largely a machine or line calculation. The original roots of OEE calculation were in human performance and we saw a way to isolate the human impact to this important metric of overall productivity.
How: Parsable’s Connected Worker Platform lives in the cloud and your teams execute their work and collaborate with one another through native apps on iOS and Android devices. Every action is measured like a continuous time and motion study.
To get companies further even faster, we've now added OEE 2.0 Connected Worker Accelerators, which provides out-of-the-box processes for changeovers, maintenance, and safety, as well as the dashboards to measure these disciplines individually and holistically. This means you get up and running fast and begin closing OEE gaps in just weeks. You then leverage the continuous insight to make better decisions faster to improve performance as your operational systems change.
The key to this new insight is surfacing the “dark data” of human action to provide a clear picture of what needs to change. As an example, for one of our customers, executing an order in SAP tracked just eight steps; the equivalent process in Parsable tracked 208 steps. This meant that this customer could now chart, graph, and make data-driven decisions on parts of their process that were never visible before.
What: The OEE 2.0 for Connected Workers accelerators include pre-built processes and dashboards for:
These accelerators allow customers to isolate, measure, and act on actual performance every day. OEE moves from a lagging measure of performance to an active and live assessment surfacing the real levers for better performance. The advantage of these Accelerators is that you don’t have to build
Many organizations focus on the technical side of procedural adherence (documentation and training), but don’t do so well with the behavioral aspect. Often the first indicator of a procedural or process problem is when a major malfunction occurs, a catastrophic event. Smaller, less obvious issues result in major loss, but are often not addressed at all. To improve outcomes, we must shift values, engage the organization in different ways and establish new behaviors that are leading indicators of procedural and process adherence.
“When it comes to digital tools and things like that, that first part of the revolution, is going to be to make your existing workforce productive.”