Proactive measures: Continuous improvement

One of the functional modules of the process management software d.production supports operators, technicians and project managers in their work as part of a continuous improvement process (CIP).

Automatically generated dashboards replace the time-consuming process of collecting facts on the whiteboard.

Work more effectively with software support 

 

The reduction of rod breaks is a powerful example of  the potential offered by Hauni Digital’s solutions in the short- and long-term optimization of any production.

Rod breaks are one of the five main reasons for stoppages in any production environment. Hauni Digital’s software solutions provide operators, technicians and project managers with effective support for eliminating these problems – significantly reducing the team’s workload. The solutions approach the challenge from three angles: short-term problem solving, continuous improvement processes and prevention.

 

Responding to difficulties at short notice

 

Solving a problem with rod breaks during ongoing production requires a quick response, targeted measures and a final test to confirm the success of these measures. The software module d.uptime provides the operator and responsible technician with everything they need to identify and understand the cause of the problem, implement solu-tions and verify and document their success. Less experienced employees, in particular, benefit from the step-by-step instructions as well as the parameters and settings provided by the software.

 

Proactive improvement process


To generate continuous improvements in the area of rod breaks and avoid negative rogue events in the production process in the medium and long term, companies must put a proactive continuous improvement process at the heart of their corporate culture. This includes establishing standards and regular meetings.

The digital process management software d.production helps businesses to prepare and manage these meetings efficiently. It also supports them in finding and adhering to optimal standards as well as incrementally developing and refining these further.

 

Preventive measures for the future

 

Artificial intelligence (AI) is gradually finding its way into the tobacco industry’s production processes. The vision is to create the “lights-off factory”. Solutions from Hauni’s d.AI range are already being used in automation, continuous learning processes and prevention-oriented  optimization. For example, d.OEEbooster constantly monitors machine behaviour. Insights gained from high-resolution machine data enable the AI to make clear recommendations that keep machines in optimum condition over the long term and prevent a decline in performance data.

Regular team
meetings and reviews

 

Challenge

The regular analysis of a production line for defects, failures and process errors, the most frequent causes of stops and the success of measures implemented requires extensive preliminary work by everyone involved. Operators and technicians have to collect all the necessary information, evaluate it, document it on whiteboards and update it daily. Project managers face the daily challenge of preparing for meetings by consolidating and analyzing all the necessary data.

Support by d.production

  • Automated, paperless data acquisition and shift analysis replaces manual work
  • Consistently high data quality
  • Automated comparisons
  • Automatic performance measurement
  • The software’s Auto Dashboard simplifies the process of compiling and analyzing all the data
  • Aggregated dashboards ensure transparency and quick decisions regarding targeted measures
  • Centralized storage of standards and changes simplifies access and exchange of information

Decision on measures and
optimization of standards

 

Challenge

In each meeting, solution approaches and measures must be defined, standards set or adjusted, and the status and decisions documented for
follow-up.

Support by d.production

  • Central document storage and retrieval
  • Central storage of standards for easy access and shared use
  • Retrieval of all pending tasks in their most current version at the workplace and via smartphone

Implementation in shift
and daily operations

 

Challenge

To implement the adopted measures, it is necessary to retrieve, compare and verify all the tasks, standards and relevant centre lines. The pending clean, inspect and lubricate (CIL) tasks must then be performed, error handling processes initiated where necessary, solution approaches implemented and status and results documented.

Support by d.production

  • Central document storage and retrieval
  • Uncomplicated retrieval on the line
  • Automatic detection of deviations from centre lines