At TT PSC, we believe that manufacturing leaders should rely on reliable, real-time data to achieve the real goals of Industry 4.0 (r)Evolution. This data can build knowledge and awareness and identify actions requiring improvement.
In the Lesson Learned Explained series, we present examples of completed projects along with insights. We hope that this short material will help you avoid at least some of the pitfalls on the way to Digital Transformation.
Challenge: Replacing paper-based reporting systems on the production floor
A client, a leader in the glass packaging manufacturing sector, identified the need to implement an integrated production data management system to replace outdated, manual reporting methods. The key requirement was to automate reporting processes in the areas of production, maintenance, monitoring of technical parameters, and management of Kaizen initiatives. The solution was expected to revolutionize information flow by providing task lists for each shift and supporting the full digitalization of data to enhance operational efficiency.
Solution: Implementation of an operational data management system
In response to the client’s needs, a dedicated system for managing checklists and maintenance processes was designed and deployed. The platform was integrated with existing ERP and MES systems, enabling seamless real-time data capture. The system generated detailed operational reports and provided advanced dashboards for monitoring the performance of production processes, allowing the analysis of both current and historical data. Additionally, data visualization at the production floor level was aimed at improving transparency and supporting faster decision-making.
Implementation Challenges: Limited adoption of the technology by end users
Despite the system’s advanced features, its adoption rate among operators was significantly below expectations. The production teams, who were accustomed to using paper-based reports, were hesitant to transition to the new platform. A thorough analysis revealed that the primary obstacle was the user interface’s insufficient ergonomics, particularly in the industrial environment where operators wore protective gloves. The touchscreens were difficult to use in such conditions, leading to a low level of comfort and reduced productivity.
Adjustment: User interface optimization to meet specific operational requirements
To enhance the system’s usability, a detailed UX audit was conducted, resulting in several changes to the user interface. The interface was adapted to the production floor environment by significantly simplifying navigation and enlarging key graphical elements, such as buttons and selection fields. These changes allowed for easier use of mobile devices like tablets, even when wearing protective gloves. The optimized ergonomics of the system positively impacted operator comfort and increased their efficiency.
Results: Increased system adoption and improved operational efficiency
Following the user interface adjustments, the system’s adoption rate on the production floor increased significantly. Operators began using digital tools for reporting more frequently, which contributed to the gradual elimination of paper documentation and improved data accuracy. Automated reporting processes facilitated smoother information flow and better management of production data, while also supporting initiatives related to process optimization.
Conclusion
The digitalization of reporting in glass packaging manufacturing initially faced challenges due to the system’s interface not being suited to the operators’ actual working conditions. However, the introduction of key UX changes allowed for the successful implementation of the solution and significantly improved operational efficiency. This project highlights the importance of considering the real needs of end users when deploying new technologies in the industrial sector.
The goal of innovation is to deliver a complete experience, not just an application. Simply implementing a new solution did not yield the expected results. That’s why it’s crucial to involve end users as early as possible and at every stage of the project.
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Check out other implementation examples below and the lessons learned from them.
