Getting Off of Paper In Manufacturing

Illinois manufacturer, Versatech, recently underwent a project to reduce their reliance on overtime work. A major component of the excess overtime labor that they identified was related  — directly and indirectly — to a reliance on paper tracking and manual processes. Getting off tracking and paper, and a reliance on spreadsheets would allow them to reduce overtime labor costs and ultimately improve the accuracy of their data as well. Versatech leveraged the SensrTrx application to replace their paper system. SensrTrx would now start auto collecting information from their machines and display it automatically in dashboards across the organization.

“SensrTrx is so much easier to use… it is almost dummy-proof” – Matt Perry, Production Supervisor

Verstech found that their reliance on paper had in-fact affected their overtime labor costs quite a bit; however, they also learned that it had been negatively impacting OEE and several other important internal company metrics as well. Check out the recent case study they performed to learn more about their achievements and what they did to get off of paper.

Below is the summarized account of Production Manager, Matt Perry. Further information can be found in the official case study linked above.

reduces downtime

How did you start getting off of paper?

We implemented SensrTrx because of the short implementation time, this was a big part of it. This allowed the company to automatically collect the data from machines that were being tracked on paper. It made these processes easier…

  • Looking at scrap detail
  • Evaluating downtime detail
  • Seeing what regular production looked like
  • Being able to look at this info multiple times a day to see when it was actually shifting

What benefits were of reducing the reliance on paper tracking?

It made it much easier to track downtime details and find root causes of problems; as long as we were getting the right data into the system. This made it much easier for us to see where we needed to focus on repetitive issues and drives improvement activity.

What was the highlight of using automated data collection and visualization?

  • Easy of use and versatility — it’s just much better when you’re not relying on paper
  • It took less than a minute to change scrap codes, and on older systems, it can be a 2-hour ordeal
  • It made it so I could dig out what ever data I need
  • Gave us a much better ability to dive down deep into specific issues; both as they happen and historically. No more wading through old prints.

What are the future plans for the project?

Inventory. We want to figure out a way to do a QC hold. We also want to try to get more granular in the data we gather so we can dig into things with more detail. We need the deeper details or we can’t fix some of the more sophisticated problems that might exist.

Advice for using SensrTrx for other users?

The devil is in the details. You can dive as deep as you want with SensrTrx, so take some time to look at everything.

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