CHALLENGE: In today's competitive market, manufacturers must do more for less while maintaining the product safety, quality, and consistency that customers expect. Manufacturers need an agile solution to handle the high variation in the packaging processes to achieve "right-first-time" results and increase overall efficiencies with a reliable, repeatable solution.
Part of the challenge lies in issues of employee retention and retirement. An ARC study on human reliability (Major Component of the Process Industries Skill Gap Solution ©2011) found that 20,000 years of experience walks out the door with 100 experienced plant operators who retire this year and that 2 million experienced professionals retired between 1998 and 2000 with only 200,000 new technically based graduates replacing them.
Another part of the challenge lies in resolving persistent time- wasting, error filled, inefficient paper systems that can cause operations errors and product issues. A BearingPoint study ("The Role of MES in Product Compliance"), found that enterprises will spend 10 times more on quick-fix compliance solutions than they will by taking a long-term approach.
If you are tired of your packaging process's inefficiencies, ask yourself "What if you could turn complex, highly variable packaging into a smart and efficient process?"
SOLUTION: Imagine training a new employee to perform line changeover within the first day on the job. Or, imagine hiring a new employee to assume the duties and skills of the 20-year line leader who recently retired. How quickly can you do this today? By embedding everyday process knowledge into an electronic system, you can ensure you’re producing consistent quality product every time, regardless of operator years on the job. This can greatly decrease employee training time, allowing you to bring a new person up to speed faster than ever before. The Syncade suite embeds process knowledge into a smart system that drives employees to perform the right actions in the proper sequence without having to rely upon years of personnel knowledge. You can now utilize your staff in the most efficient way possible making EVERY operator--new or experienced-- your BEST operator.
Next, imagine a smart system that eliminates error and embeds quality in the process for right-first-time processing. A system that turns complex, highly-variable, often paper-driven processes into reliable, consistent, right-first-time and every-time processes. Whether you’re manufacturing with an order-based operation or delivering as much product as possible, automating everyday activities can take the guess work out of: knowing what materials and quantities to use, performing calculations, setting up equipment, pulling samples and recording data, changing over equipment, purging lines, visualizing exceptions to the process, and more.
Embed knowledge. Increase work efficiencies on and off the packaging floor. Increase right-first-time. Ensure consistent, quality product. Deliver product to market faster.
