Recently, I co-founded Augmentir with three key executives from my prior start-up, ThingWorx, and have been exploring Enterprise AR. ThingWorx was the company that created the Industrial IoT application platform category and was arguably the most successful start-up in the IIoT space, getting acquired by PTC in early 2014. The acquisition of ThingWorx was the […]
Recently, I co-founded Augmentir with three key executives from my prior start-up, ThingWorx, and have been exploring Enterprise AR. ThingWorx was the company that created the Industrial IoT application platform category and was arguably the most successful start-up in the IIoT space, getting acquired by PTC in early 2014. The acquisition of ThingWorx was the first, non-distressed acquisition in the space and directly led to the wave of acquisitions that have reshaped the IIoT landscape.
Prior to founding Augmentir, I did a fairly deep dive into the marketecture of Enterprise AR and found that it reminded me of the early IIoT space — fragmented with lots of companies occupying niches:
Custom solution builders around Smart Glasses
Vertical Solution Builders
Smart Glass vendors
Technology providers
And more
Gartner’s recent release of the IIoT “Magic Quadrant” was both reaffirming and disappointing. It was personally reaffirming to see that ThingWorx, under the leadership of Jim Heppelmann, CEO of PTC, occupies the “Most Magic” position in the IIoT space. However, it was disappointing to see that after ten years, the IIoT space has not yet “crossed the chasm” as evidenced by the fact that no vendor is in THE Magic Quadrant.
Why would IIoT, a space that has so many compelling ROI stories, still be stuck between early adopter and mainstream? I have a point of view on this — while IIoT solutions can be extremely valuable and transformative, they have to be easy to own in order to achieve mainstream adoption. IIoT is anything but “easy to own”: this starts with the high friction, traditional enterprise sales process, long pilots, expensive, “Value-based” pricing, long, risky implementation cycles, and vendor lock-in/high switching costs. This makes it hard for even large enterprise businesses to fully adopt, and given these dynamics, it’s easy to understand how Small and Mid-sized businesses have been essentially locked out of the IIoT opportunity.
Unfortunately, in Enterprise AR I see the same dynamics unfolding. High friction sales and POCs, combined with long implementation cycles and high prices, will keep Enterprise AR mired in the early adopter phase. Already, sales of Smart Glasses for the enterprise are hugely disappointing, signaling that the market is unfolding much more slowly than analysts have projected. This will disappoint many investors and dash the hopes of many startups who believe in market projections, not realizing that they are a key part of the problem.
Certainly, we need a new direction if Enterprise AR has any hope of ever crossing the chasm and achieving mainstream adoption.
https://www.augmentir.com/wp-content/uploads/2018/07/augmentir-blog.jpg6301200Russ Fadelhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngRuss Fadel2018-07-13 02:19:332023-12-13 19:23:21Will Enterprise AR suffer the same fate as Industrial IoT?
AI and connected worker technology is helping frontline managers combat employee burnout and improve engagement and retention.
Industrial work comes with an immense amount of stress. Without providing the worker with the right level of support, this stress can lead to increased errors, poor work performance, and eventually, employee burnout. Recently, Gallup reported that 76% of employees experience some form of workplace burnout. This not only affects performance and productivity but much more, including engagement and employee retention.
To offset employee burnout, managers should aim to:
Reduce employee stress
Remove roadblocks ensuring their workers have the proper tools to complete their tasks
Ensure workers are a good match skill-wise for the work they are doing
Give workers a say in how the work is completed
Empower workers to believe that the work they are doing is valued and important
In a 2022 Gallup poll, 79% of employees responded as not being engaged at work, this same poll found that most employees don’t find their work meaningful and do not feel hopeful about their careers.
When supporting workers and battling workplace burnout, there is no “one size fits all” answer, and many organizations are realizing that taking the same approach for “desk workers” does not account for the many and uniquely different needs demanded by frontline or “deskless” workers. Managers must keep in mind these needs when combating and detecting burnout and boosting employee engagement.
Artificial Intelligence (AI) and machine learning-based technology combined with a worker-centric approach can help tremendously in this respect, accounting for the human element in industrial operations while still taking advantage of innovations.
Using AI to Enhance Worker Experience and Reduce Burnout
By utilizing the capabilities of connected worker platforms and AI, companies can take a proactive approach to reducing stress and preventing employee burnout.
The meteoric rise of AI tools like ChatGPT and natural language processing has created a surge in interest in all things AI and while it’s not a cure-all, AI has the potential to be extremely effective in helping workers get access to the information and support they need while on the job, as well as predicting, detecting, and reducing workplace burnout. By taking highly granular connected worker data and using AI to filter out the unnecessary portions, industrial operations are able to not only improve tasks and productivity but better support and empower frontline workers. Organizations can use AI to engage employees by:
Creating communication touchpoints and streamlining communication
Pairing workers and tasks based on skill level
Suggesting training and certification opportunities for upskilling workers
Create feedback paths so employees have a say in how tasks are completed
To complement AI and software platforms, organizations can implement other tools such as wearable devices, mental health applications, and more to aid in engagement efforts. Finding the right balance and combination is key for knowledge exchange and conversation – making employees more engaged within the team.
The Human Element
It is important to take advantage of new technologies and implement them where needed, but technology by itself is not the answer. Finding a balance between technology integration and a worker-driven approach is key and it is paramount that the true needs of the workforce are not forgotten. Although AI and machine learning-based technology can help tremendously with detecting and reducing employee burnout, it has its limits and can only do so much. Technology cannot replace how workers feel and how they interact with management on a day-to-day basis. And at the end of the day, AI can only augment employees and should be used to empower them, never to replace them.
https://www.augmentir.com/wp-content/uploads/2023/03/human-side-of-ai.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-03-14 03:05:062023-12-13 19:12:35The Human Side of AI: Supporting Workers to Reduce Employee Burnout
Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.
First time quality plans, or first time right plans, are a manufacturing approach that ensures all processes on the production floor are performed properly the first time, every time. A FTQ plan is a document that outlines which standards, practices, and resources are needed to execute those procedures to create high-quality products.
A quality plan is a must to guarantee zero-defect goods and prevent the need for any rework or scrapping of parts. If a manufacturer’s goods do not meet internal, industry, or consumer standards, then it’s more than likely that they won’t sell.
Every product development project should have a quality plan in place. Read on to learn how to create a first time quality plan document:
A FTQ plan, when executed correctly, can help you reach 100% FTQ, which means zero defective products. As a result, it boosts consumer trust in your product and your company’s credibility. It’s a good way to cover all bases to ensure nothing is left out, from product goals and objectives to testing requirements and distribution.
A FTQ plan may contain the following:
Goals and objectives, including item specifications, cycle time, materials, cost, etc.
A list of procedures
Worker expectations and responsibilities
What industry standards should be applied
A method for measuring quality
Testing requirements
Updates to procedures
3 steps for creating a FTQ plan
Developing a quality proposal is a great starting point for making sure that products are made right the first time around.
The steps below explain how to successfully create first time quality plans and strategies that give your manufacturing operations a competitive edge.
Step 1: Conduct an initial audit
Creating a FTQ document begins with an initial audit of the suppliers a manufacturer will use. An audit is the perfect way to gauge whether a supplier matches your product expectations and meets your quality standards.
An audit may check:
Materials
Equipment/machinery
Procedures
How well staff is following processes
Step 2: Determine if suppliers meet product specifications
Next, it’s vital to check whether a contractor can produce items that meet your standards and specifications. It’s also important to establish a partnership and a solid communication process with your supplier so that nothing falls through the cracks.
Step 3: Implement quality inspections
Lastly, a well-formulated plan includes quality inspections of each production run and product before distribution. This is usually completed by quality inspectors on the shop floor.
Inspection criteria typically includes:
Order and shipment sizes
Packaging and appearance
Product performance
Once the inspection is done, a report should be created and submitted to the quality manager before any products are shipped. This report also serves to measure quality metrics and places for improvement.
First time quality with Augmentir
Augmentir is a connected worker solution that allows industrial companies to digitize and optimize all frontline processes that are part of their quality management strategy. Augmentir’s complete suite of connected worker functionality is built on top of Augmentir’s patented Smart AI foundation, which helps identify patterns and areas for continuous improvement.
https://www.augmentir.com/wp-content/uploads/2023/04/first-time-quality.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-04-23 02:47:492023-12-13 17:49:44How to Create First Time Quality Plans
Smart Skills Management software is helping manufacturers bridge the gap between training, skills, and work to build a more resilient and agile workforce.
Where are you on your journey with adopting new and emerging technologies? Many manufacturers are jumping on the bandwagon for some of the latest tools that provide digital guidance to workers. Maybe you decided to implement digital work instructions to help workers safely and efficiently perform tasks. Or maybe you’ve bought skills management software to help you catalog and organize the skills and capabilities of different workers. But are either of these enough on their own to achieve all your production goals? Possibly, but unlikely.
Digital work instructions on their own deliver standard work guidelines but fail to consider the unique skills of each worker. Standalone skills management programs may offer a highlight reel of the skills and certifications of your workers but neglect to capture performance in real-time to provide accurate skills evaluations. Nor do they offer personalized training content needed to ensure workers perform their absolute best. Can we agree then these two features should go hand-in-hand?
One cannot exist without the other: Blending skills into the flow of work
Turnover was infrequent so line supervisors knew everyone on their team and their current skills and endorsements, making it easy for the supervisor to assign work safely and optimally
Investments in training, reskilling, and upskilling were performed either in a one size fits all approach or through a purely subjective or anecdotal approach
Today, however, a different situation exists.
Line supervisors are dealing with team members that they don’t know well, new ones starting every day, and experienced ones leaving. This creates safety issues and makes optimally assigning work difficult as not only are the workers variable, but their skill levels and certifications are a constantly moving target.
An integrated, closed-loop skills management system is the solution for this era of high workforce turnover and absenteeism.
Skills management solutions that combine skills tracking capabilities with connected worker technology and on-the-job digital guidance can deliver significant additional value. Data from actual work performance can inform workforce development initiatives allowing you to target your training, reskilling, and upskilling efforts where they have the largest impact.
It can generate an abundance of valuable data to provide tailored training support and skills endorsements and identify workforce opportunities. What else is possible? Imagine reducing training costs, optimizing job scheduling, increasing safety, and improving productivity. And now consider what will happen when you add smart technology to this all-in-one package.
The power of smart digitization! Skills management and digital work instructions together boost productivity.
According to Deloitte, organizations are shifting to a skills-based approach to meet the demand for agility, agency, and equity. Connected worker solutions that combine skills management with digital work instructions, collaboration, and knowledge management are uniquely suited to optimize today’s variable workforce. AI-generated insights are pulled from patterns identified across all work activity in real-time. These insights identify where new and experienced workers may benefit from either reskilling or upskilling.
This combination of smart digital technology can also leverage your training resources, such as instructional videos, written instructions, or access to remote experts, to deliver personalized guidance for the worker to perform their best. These tools intelligently work together to help you assign workers to procedures based on required skill levels. No second guessing! Augmentir is the only smart connected worker solution to intertwine these management tools with AI making it a powerhouse for optimizing your operations and meeting production targets.
Learn how Smart Skills Management software is helping manufacturers bridge the gap between training, skills, and work to build a more resilient and agile workforce.
Download our latest eBook – The Future of Work: Connecting Skills Management with Standard Work.
https://www.augmentir.com/wp-content/uploads/2022/09/skills-management-and-digital-work-instructions-better-together.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2022-09-28 14:07:192023-12-13 17:44:35Like peanut butter and jelly, skills management and work execution are better when served together
Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.
Quality assurance(QA) and inspection procedures work hand in hand to ensure customers receive quality products free of deficiencies. But what do the terms mean exactly?
QA is a systematic process that manufacturers use to ensure that a product or service meets the requirements for distribution. QA inspections are a subset of that process, checking products before they go off the line. Inspections are a crucial part in troubleshooting and fixing product defects, making improvements, and maintaining compliance.
These inspection procedures should be standardized and digitized to create a quality assurance system that ensures workers have access to the correct procedures and that tasks are performed in a standard manner to avoid errors on the production floor. This results in reduced defects, optimizes quality data collection, and decreases the need for rework.
Explore the following topics to learn how to decrease mistakes on the shop floor when you digitize and standardize quality assurance procedures:
Standardization and digitization work in tandem. Let’s break down the two concepts to get a better idea of how they work.
Standardizing means developing a set of rules for how tasks should be completed. It boils down to this: When you standardize tasks, you’re giving your employees an established, time-tested process to use.
When done right, standardization decreases ambiguity, enhances productivity, boosts quality, and increases worker morale.
Digitization, on the other hand, involves converting information into a digital format. Keep in mind that it’s the information you are digitizing, not the processes or procedures. Automating your work processes using a single system, like a connected worker platform, makes everyday operations much faster and easier to accomplish. Enhancing this further with AI-driven analytics and process optimization empowers manufacturers and frontline personnel with the right tools for quality data collection and inspection procedures.
How standardizing QA and inspection procedures reduces errors
According to LNS Research, to digitize quality assurance processes, manufacturing leaders must leverage emerging technologies. This allows them to achieve step-change improvements across operations. When you standardize quality assurance procedures, you’re ensuring processes are completed using best practices and proven methods.
Think of it this way: When workers complete tasks using their own choice of tools, platforms, or reporting mechanisms, it’s harder to measure and evaluate which procedures are bringing value and which ones are not. It also leaves a lot of room for human error and inefficiency.
QA and inspection procedures should be standardized so that a worker’s way of doing things aligns with the company’s overarching objectives. If you don’t standardize inspection procedures, you’ll have a more difficult time pinpointing product deficiencies and worker errors.
Smart, connected worker platforms and AI-based software allow manufacturers to standardize processes across all units, creating a single source of truth for a truly optimized procedure that can be audited and verified, resulting in fewer errors, reduced defects, and more expedited inspections overall. Every procedure, regardless of how often it’s performed, can have guidelines that define the scope and methods for how to perform it. This in turn ensures a higher quality result every time.
How digitizing quality assurance procedures minimizes mistakes
Converting your paper-based QA procedures to a digital format is one of the smartest things a manufacturer can do. From there, you can set up a unified system to improve QA assurance processes.
Workers are only human, and quality assurance systems safeguard the production process. It identifies mistakes as they happen and uses communication tools to reduce the risk of error. Other strategies such as a “first time quality” (FTQ) or first time right plan enhance standards, practices, and resources to ensure all processes on the production floor are performed correctly the first time.
Deploying an integrated system makes it easier to:
Gradually improve your production processes
Standardize your QA methods
Digitize manufacturing processes
Connectivity and connected worker technology empowers all workers to do their jobs better and in a timelier manner. It also gives managers the opportunity to track how well employees are carrying out standardized QA procedures and inspections. When coupled with AI-driven analytics that can process the massive amounts of data connected workers generate, manufacturers are able to derive better insights, faster, and with higher reliability. This essentially transforms frontline workers into quality assurance sensors that further enhance and empower quality inspections.
If you’re still using paper checklists to track procedures, you’ll never see beyond what’s in front of you. By digitizing analog paper practices you are enabling better quality data collection and inspection procedures and strengthening your overall manufacturing operations.
Thankfully, Augmentir’s connected worker solution gives real-time visibility into all operational processes, from anywhere. Industrial companies use our breakthrough system to standardize and digitize quality assurance procedures.
If you are interested in learning for yourself why companies are choosing Augmentir to help standardize and digitize their quality assurance procedures – reach out to book a demo.
https://www.augmentir.com/wp-content/uploads/2023/07/standardize-digitize-quality-assurance-manufacturing.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-07-19 17:50:232023-12-12 22:09:12Why You Should Digitize and Standardize QA and Inspection Procedures
Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.
Beginning in mid-2022 and now increasing in 2023, there is a significant trend of companies moving away from earlier investments in connected worker software tools to Augmentir’s Connected Worker Platform.
Early adopters and pioneers of V1.0 connected worker tools and technology deserve respect for leading the charge into Industry 4.0 and the concept of a connected workforce. However, we also admire those leaders who realized there are more transformations and improvements to make – such as value in the data from your connected workers and incorporating AI-driven solutions to make sense of that data. These innovative leaders dared to adapt, continue innovating, and replace the connected worker software systems that were not solving enough of the challenges faced by the modern workplace.
By combining AI-powered software and smart connected worker solutions, manufacturers are able to get next-level results and improve frontline worker productivity, engagement, and safety.
Following in the Footsteps of Industrial Transformation Leaders
According to LNS Research (a leading analyst firm in defining the connected worker space), the business case for connected worker software continues to grow, and solutions that incorporate emerging technologies like AI are leading the way. In fact, LNS states that Industrial Transformation Leaders (IX Leaders) are two times more likely to use AI-enabled advanced analytics capabilities. These leading manufacturers are supporting their frontline operations with AI-based technology for training and skills development, real-time worker performance support, and providing dynamic and personalized content.
Here at Augmentir, we have seen quite a few companies that fall into the category of the courageous, understanding that they needed to continue adapting for their business to thrive.
We have been honored to be recently chosen by several global leaders as their connected worker V2.0 solution, including:
one of the largest paint manufacturers in the world
one of the largest agricultural companies in the world
one of the largest food manufacturers in the world
one of the largest manufacturers of batteries in the world
All of these world leaders recognized that their current connected worker software solutions had become insufficient and that they needed a smarter, more complete solution to help them overcome their frontline workforce challenges and current business obstacles.
Here are three key takeaways you can use from these companies that went back to select a new connected worker solution:
Don’t be afraid to make a change that will have a positive impact on your business, even if you are the one who made the initial decision.
If you have experience choosing early connected worker tools, build on that experience. You are ideally situated to identify gaps in processes and improvement needs; and know best which tools to use to address the overall operational needs of the business.
Use your prior experiences to build processes for re-evaluating connected worker solutions from the perspective of already experiencing one fully deployed.
In one example, a global manufacturer invested in an early connected work tool and had been using the tech for nearly 4 years. However, once they decided they needed a new solution, they then went back to evaluate the market for the right tool. They made a list of selection criteria they knew they wanted from this new solution, from that they looked at approximately fifteen (15) connected worker vendors, and from there they narrowed down to the three (3) they ended up testing. They even included having a couple of integrations in their POC as they knew that an integration into their ERP, Quality Management, and Asset Management systems was something they needed, and they had poor experiences previously with vendors overcommitting.
Pro Tip
We suggest anyone evaluating a technology use this same approach – include integrations as part of your Proof-of-Concept to ensure that you are not getting hypothetical answers to hypothetical questions, and that the solution meets your true business needs.
What our customers tell us
Here is what customers are telling us they are looking for in a V2.0 connected worker solution, and the reasons they changed to Augmentir’s Connected Worker Platform:
Ease of Use: Augmentir prioritizes a user-friendly experience. Its intuitive interface and workflow builder makes it easy for employees to adopt and use the tool effectively. This can result in faster onboarding and increased overall productivity.
Augmented, Personalized Work Instructions: Augmentir provides a workflow and content creation environment that allows you to digitize standardized work instructions, and adjust content and in-line training to suit the needs of individual workers. This optimizes performance and speeds up onboarding time for new employees.
Upskilling and Reskilling: Augmentir’s ability to deliver formal skills and learning in the flow of work means a worker can stay current in their needs, continue to grow in their role, and build a structured career path within their company. This approach appears to be driving increased retention and job satisfaction.
Workforce Optimization: Augmentir’s ability to assess in real time who is available to work on any given day and then balance the skill level best suited for a task with the available workforce offers optimal productivity based upon what you have to work with on any given day.
Digitizing Complex Workflows: Most solutions on the market allow you to digitize simple workflows. With Augmentir, manufacturers can build complex workflows that satisfy use cases that are unique to their business, and extend those workflows to support greater integration into their business processes.
Industrial Collaboration: Augmentir enables remote collaboration among workers and experts. This functionality is particularly useful when experts are not physically present at the job site. Remote experts can guide workers through AR annotations and audio/video communication, fostering knowledge sharing and faster problem resolution.
Continuous Improvement: Augmentir focuses on driving continuous improvement within organizations. It leverages AI to analyze data from worker interactions and identifies areas for improvement. This data-driven approach allows companies to optimize processes, increase productivity, and reduce costs over time.
Integration and Scalability: Augmentir offers integration capabilities with existing enterprise systems, such as enterprise resource planning (ERP) or manufacturing execution systems (MES). This ensures seamless data exchange and workflow integration. Additionally, Augmentir is designed to scale with the organization’s needs, accommodating both small teams and large enterprises.
Analytics and Insights: Augmentir provides robust analytics and reporting features driven by AI-powered solutions and focuses on AI as a core component of Connected Worker V2.0. This allows managers and supervisors to gain valuable insights into worker performance, task completion times, and areas that may require additional training or support. Data-driven analytics can aid in identifying bottlenecks, optimizing processes, and making informed business decisions.
Customization and Flexibility: Augmentir allows organizations to customize their work instructions and workflows to fit their specific needs. This flexibility enables the tool to adapt to different industries, processes, and work environments.
If you are interested in learning for yourself why companies are choosing to change to Augmentir over their current connected worker solution – reach out to book a demo.
https://www.augmentir.com/wp-content/uploads/2023/06/darwin-in-manufacturing.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-06-07 14:44:572023-12-12 21:54:03Darwin in Manufacturing: The Evolution of Connected Worker Software
Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.
Following quality control (QC) and quality assurance procedures in the food industry is imperative to ensure product quality and consumer satisfaction. Today’s consumers demand safe, reliable goods that meet all quality inspection protocols. The last thing you want is for a product to get recalled because of potential health concerns.
According to Food Manufacturing, quality control is one of the most important aspects of the food and beverage industry. Manufacturers who perform routine inspections of products during each stage of the production process significantly increase their chances of delivering items that are free of health hazards and liabilities. But beyond avoiding these concerns, standardizing and digitizing quality procedures benefits the entire operation.
Ultimately, preventing and catching quality issues can boost product quality, reduce waste, raise profits, increase brand reputation, and avoid media or food safety disasters. Learn more about QC and assurance in the food industry and how to improve it as we discuss:
There are certain QC measures you can take to ensure that all goods meet quality standards, from regular machine inspections to worker training. They fall into two general categories: preventative and reactive.
Preventative (proactive) quality control: Minimizing the number of deficiencies begins with implementing preventative QC solutions. When workers can catch mistakes before they even happen, they prevent product defects. Preventative QC measures should be practiced on a routine basis and can range from inspecting machines and equipment to offering employee training opportunities. By providing workers with real-time information and guidance through mobile, connected worker solutions, manufacturers enable them to make better decisions about product quality, reducing the risk of errors and identifying potential quality issues before products are shipped to customers, reducing the risk of product recalls, and preserving consumer trust.
Reactive quality control: Catching every defect on the production floor is nearly impossible, even if the most fool-proof strategies are taken. That’s why creating a plan of action ahead of a crisis can help solve quality issues as they happen.
What to put in your plan will depend on the potential problems. For example, you can include specific instructions on what to do if machinery breaks down or stops unexpectedly. It’s vital to collect any data at this stage. Analyzing this data can help you improve preventative quality control in the future to make sure the same problems don’t happen again.
Pro Tip
By utilizing AI and modern, digital technologies, companies can connect, engage, and empower frontline workers to drive quality improvements, resolve quality issues faster, and share timely insights with teams across the value chain.
Keep in mind that practicing quality control in the food industry should be part of every manufacturing process, from product ideation and development to production and delivery. Problems can develop at any time, so it’s crucial to follow protocols at every stage of production to prevent even the slightest of mistakes.
All workers should also uphold QC and assurance protocols in their everyday tasks to ensure continuous product improvement.
Better organization of equipment can also help workers understand how the action of one affects the other to solve any potential problems. This is another benefit of integrating your asset hierarchy with a connected worker solution. In a nutshell, strong hierarchies are a solid foundation for proper maintenance management and reliability.
How to improve QC and assurance procedures in food production
Effective quality control and assurance procedures prevent defective food products from making their way into grocery stores and homes. That’s why manufacturers should document the quality of their goods at every stage of the operational process. Strategies like first time quality (FTQ), or first time right, plans coupled with smart, connected solutions help decrease product deficiencies and increase customer satisfaction.
Manufacturing firms in the food industry must follow specific requirements set by the Food and Drug Administration (FDA), Good Manufacturing Practices (GMP) system, and the Hazard Analysis and Critical Control Points (HACCP). The guidelines set by these regulatory bodies can give businesses a better idea of how their processes should look and what data they need to collect and report.
Data should be collected for real-time production processes. These vary by product but may range from product chilling and thermal processing to testing raw materials for metal toxins and other chemical deposits.
The following steps provide a roadmap for how to improve quality control in the food industry.
Step 1: Source the correct ingredients
A successful assembly line run begins with finding and using the correct ingredients. Some things to think about when deciding which ingredients to choose: where the raw material was sourced, when, and its condition.
Step 2: Include an approved supplier list
Make sure that each ingredient has an approved supplier list. A good rule of thumb is to include three vendors per ingredient and record the ingredient with each supplier’s name, address, and code number on the list. The more information you include, the better. Having an approved vendor list ensures that all parties are properly vetted by the manufacturing firm and meet its requirements for quality and distribution.
Step 3: Document product and recipe creation
Documenting how each food item is made and its recipe helps set the quality standards for finished goods. This documentation can also be useful when improving product development in the future. Your document should include the types of ingredients used, their codes, batch yield, percentage formula, and more.
Step 4: Catalog production procedures
It’s also critical to log all the details of a production process, including how materials should be delivered, the appropriate conditions for storing food, what order each ingredient should be added to the batch, what tools are needed, and who is in charge of each task.
Note that this step is different from documenting product and recipe development because it includes the actual instructions for carrying out each procedure. For example, a worker may be asked to preheat the oven to a certain temperature as part of ensuring the food is ready for customer distribution.
Step 4: Record real-time processes
Machine operators should record in real-time every detail of how goods are created during actual production. This can include factors like product size, weight, expiration date, equipment conditions, and more.
Step 5: Digitize assurance and inspection processes
AI and smart, connected worker systems help digitize and link inspections and other quality control procedures. This creates an additional layer of defense, protecting customers and preventing quality issues before they can impact production.
How Augmentir helps with quality control and assurance
Augmentir offers a smarter way to improve quality control in the food industry by effectively standardizing and optimizing quality assurance and inspection procedures for all frontline workers. With our smart, connected solutions coupled with AI-powered software, food manufacturers have improved quality control and assurance by:
Tracking and analyzing data to identify trends and opportunities for improvements
Reducing human error in inspections by standardizing and improving training procedures and processes
Transforming connected workers into human sensors who can proactively address quality and safety events that surface during manufacturing operations
Our AI-powered connected worker solutions, provide digital work instructions to help employees better perform inspection checks and reduce the number of production errors and rework.
These customized solutions also include:
Digital standard operating procedures (SOPs) for how to complete assembly line tasks. These step-by-step instructions can greatly improve workflow efficiency, increase regulatory compliance, and reduce mistakes on the shop floor.
Digital workflows that convert your paper-based processes to digital work instructions and personalize them to the needs of each worker.
Enhanced product traceability to decrease equipment setup time, reduce process inconsistencies, and better meet customer expectations. Our digital instructions help you to easily track materials from the supply chain, inventory, and across every production process.
If you are interested in learning why companies are choosing Augmentir to help improve their quality control and assurance processes, check out our quality use cases – or reach out to schedule a live demo.
https://www.augmentir.com/wp-content/uploads/2023/08/quality-control-food-industry.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-08-15 02:53:172023-12-12 21:34:15How to Improve Quality Control and Quality Assurance in the Food Industry
The benefits of digital work instructions go far beyond simply standardizing work. The real benefit is in personalized guidance and support for today’s workers.
Providing quality products consistently and on time is at the forefront of customer satisfaction. In today’s competitive market, manufacturers must execute production runs quickly and efficiently to meet customer demand. But equipment and workers can’t operate 24/7. Machines must be properly maintained, workstations require cleaning and employees need rest. This is where optimizing changeover time comes in.
Changeover time is the period that it takes for workers to adjust machines or for assembly lines to start the next product run. A changeover usually includes swapping parts, sanitizing equipment, and preparing it for the next cycle. A good rule of thumb is to keep the changeover period down to less than 10 minutes. You can keep track of your organization’s changeover time by capturing how long it takes to produce each product.
Keeping an eye on your changeover time can help you maximize production and improve processes. Learn more about how you can reduce changeover time in manufacturing by exploring the following topics:
Minimizing changeover time is a key component of lean manufacturing, a production method aimed at minimizing waste while increasing worker productivity. Implementation of this process can help manufacturers maximize uptime and cut down on waste caused by downtime.
Although there are various steps you can take to reduce it, here are some essential steps to help you get started:
Step 1: Assess your present changeover method.
It’s crucial to look at your existing changeover protocol before taking action to modify it. Try to identify which processes need optimization in order to cut down on the time between inventory runs.
Step 2: Implement single-minute exchange of dies (SMED).
Single-minute exchange of dies is a tool used in lean manufacturing to reduce changeover time to single digits. This means that a successful assembly run should be less than 10 minutes.
It’s helpful if workers have some idea of how long each task (such as switching parts, cleaning, etc.) takes during the production process. This awareness can be cultivated the more they familiarize themselves with procedures and day-to-day routines.
Step 3: Create standard changeover procedures.
Creating standard operating procedures (SOPs) and standardizing work can help with the changeover process. If there aren’t centralized procedures, changeover times will vary based on the employee, how long it takes them to clean up, set up and begin a new production run.
It’s important for procedures to contain explicit directions on how to perform successful changeovers. This can include highlighting which equipment needs to be calibrated and other machinery-related tasks.
Pro Tip
Digitizing changeover procedures can offer several benefits that enhance the overall efficiency, safety, and effectiveness of the changeover process. Digital procedures can be accessed by frontline workers through a mobile device or wearable technology, and help improve accessibility, accountability, standardization, as well as provide visual aids to less-experienced workers performing the task.
In a nutshell, having clear instructions makes it easier for workers to know what to expect when it’s time for a changeover.
Benefits of reducing changeover time
Reducing changeover time can yield a number of benefits, especially for companies producing a large number of products on a day-to-day basis.
Some of the advantages include:
Makes it easier to transition between production processes
Creates a more productive work environment
Helps to reduce equipment downtime
Gets products to customers faster
How digitization can help
Implementing connected worker solutions that digitize and optimize changeover processes can help reduce the time each changeover takes by providing explicit digital instructions customized to any given task, machine, or worker.
Digital work instructions are electronic versions of work instructions, quality manuals, or SOPs that provide necessary visual aids and real-time contextual information to help guide workers through complex tasks. These digital work instructions intelligently deliver guidance and streamline changeover processes with images, videos, augmented reality experiences, and live support from colleagues or subject matter experts.
Augmentir is the world’s first AI-powered connected worker platform that helps industrial frontline workers reduce changeover time in manufacturing using smart technology. Learn how world class manufacturers are using Augmentir to drive improvements across their industrial operations – contact us for a demo today!
https://www.augmentir.com/wp-content/uploads/2023/09/reduce-changeover-time-manufacturing.webp6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-09-03 03:11:502023-12-12 21:23:59How to Reduce Changeover Time in Manufacturing
