As per the 2010 Compensation Data Manufacturing survey, nearly 70% of companies make use of lean manufacturing techniques. Lean manufacturing is the application of best practices, tools, and principles applied in the manufacturing process to reduce waste, cut costs, streamline processes, and increase production. One of the most important practices of lean manufacturing is problem-solving. So what is lean problem solving and how can a Connected Worker platform help?  

‍To truly implement lean manufacturing principles businesses need to improve their problem identification and problem resolution process. Paper-based processes make collecting data to test and improve new processes difficult, forcing manufacturers to rely on hypothesis and intuition. Manufacturers need to make it easier for front line workers to give feedback and point out waste. This is where the Connected Worker comes in. But first let’s look at some of the ways paper based processes stand in the way of lean problem solving.

The Issue with Paper-based Processes

Ledgers, registers, and spreadsheets are becoming a thing of the past. In this fast-moving business world, companies need to have agile processes to compete in the marketplace. There are several reasons why that can’t happen through these legacy processes.

1. A slow-moving process

In an organization with paper-based processes, an issue is first written on a paper by the person who first observes it. The paperwork is then ideally passed on to the higher levels until it reaches someone capable of resolving the issue but more likely is entered in a siloed computer system where almost no one has access to the data.

2. Disjointed organization

Since information takes a lot of time to reach its destination in a paper-based system, employees work in complete isolation unaware of whether the production line before or after them is facing an issue or not. Workers don’t know about important details related to changes in the machine they’re working on.

3. Inhibits process improvement

Problem-solving is an evolving process but paper-based processes are by their very nature static. With paper-based SOPs and data capturing, management lacks the data they need to discover inefficiencies in processes and the process agility they need to improve them. Cumbersome legacy systems neither capture a problem in detail nor offer the flexibility needed to create a permanent solution, slowing down the continuous improvement process.

How Connected Worker Helps with Lean Problem Solving

Digitization has become a business inevitability. IDC estimated that by the end of 2020, around 60% of companies will rely on digital platforms to support at least 30% of their overall revenue. Many companies have either made a complete shift to the digital ecosystem or are in the midst of a digital transformation. In the manufacturing industry, Connected Worker or Front Line Worker platforms integrate workers into their environments through the devices they naturally use in the flow of work(laptops, mobile phones, tablets and Smart Glasses). This augments front line workers with the training, work execution and remote assistance support they need to do their best work.

Here is how connected workers help with improved lean problem-solving:

1. Problem Identification

Digital tools make it easier for front-line workers to identify and resolve issues quickly. Workers can seamlessly share their findings whenever and wherever they experience an issue. Instead of weeks and months of bureaucratic delays, the problem can be resolved in a few hours and prevent emerging problems from cascading into system failures.

2. Access to digital instructions and training

Paper-based SOPs and in-person training isn't an efficient way of training and upskilling employees. Connected workers are equipped with searchable, on-demand digital training that are highly visual and easy to understand no matter your worker's education or experience level. This gives them the knowledge they need to work independently and problem solve.

This digital training is  machine specific. Workers can scan QR codes attached to a piece of equipment. This contextually rich learning can include instructions on each individual step of a workflow to help standardize the process.  Not only does this give the worker a better understanding of the machine but also helps with just-in-time jobs where an inexperienced worker has to execute a certain maintenance task urgently.

3. Real-time problem solving

With the help of connected worker technologies like AR-enabled headsets or video-based instructions, remote experts can engage in solving the problem in real-time with the on site technician. An operator working in one branch of the company can connect with a subject matter expert sitting in another far off location and get assistance. This speeds up problem resolution time by providing on-site expertise without added transportation time to fly or drive to the plant that is having the problem or issue.

4. Predictive and prescriptive analytics

Front Line Worker platforms help in value stream mapping and since connected workers are collecting rich job data to contribute to problem-solving, business leaders can get in-depth information about where and how process issues are occurring. This is crucial for identifying root causes and eliminating issues.

Taking Manufacturing Forward With Lean Problem Solving

With an increased level of automation, problem resolution and efficient workflows, companies can effectively reduce waste and make their production more efficient by using connected workers to improve lean problem solving.

Atheer's AR Powered Connected worker platforms enable front-line workers to stay connected to their environment, identify issues early on, and resolve them quickly. It gives management the rich data insight and holistic visibility they need to improve crucial metrics like OEE.  

Atheer’s low code/no code Connected Worker platform can track the performance of your front-line workers and measure important KPIs to help improve efficiency and productivity. With solutions like self assist, work assist and remote assist, Atheer is the end-to-end solution for augmenting your front-line to do their best work every time.

For companies that want to increase productivity, enhance their efficiency, and boost their business growth, adopting lean manufacturing principles is a necessity. With the Atheer Connected Worker platform, they can determine possible causes for issues or bottlenecks during production and resolve them with ease.