5 Industrial Procedures that are now entirely Digital

In the age of industry 4.0, digital transformation, and smart operations, paper use is still a norm for many businesses working in the manufacturing and asset-intensive industries. To optimize procedures, increase efficiency, reduce costs, and ensure the safety of workers, many procedures can be digitalized, while paper use can be terminated.

This transformation not only presents several benefits related to the costs related to the use of paper, but also allows for the optimization of procedures and the implementation of a continuous improvement strategy.

SOPs are documents that contain detailed step-by-step instructions or checklists on how to execute a specific task. In essence, all documents describing a process or “how to” can be considered an SOP. They are crucial tools to help reduce errors, increase profitability, implement guidelines to resolve issues and overcome unexpected setbacks, and even train staff.

Paperless SOPs

Paperless SOPs are the result of the digitization of legacy documents using a digital solution. Once digitized, SOPs can be expanded by introducing easily/accessible media support (e.g., images, videos, or other media formats). These digital procedures can then be accessed using mobile devices or wearables which can provide contextualized information powered by AR markers. In essence, the digitilization of SOPs targets specific use cases, such as digital work instructions (both 2D and AR-based).

Simultaneously, AR-based SOPs, checklists, or "how to" guides can be used to deliver faster and more autonomous training, in which trainees are guided during their tasks and can access real-life scenarios in simulated environments.

Subsequently, digital SOPs can be monitored in real-time and help inform the creation of automated dashboards and reports. These reports can then be used by managers in relevant use cases including team and task management and monitoring, reports, and analytics.

Benefits

Maintenance procedures describe all actions aimed at managing machinery and equipment to increase uptime, reduce breakdowns, track ongoing issues, and ensure safe and efficient working conditions. By regularly inspecting machines and equipment it is also possible to reduce repair costs and improve productivity and sustainability.

Paperless Maintenance

Digital maintenance procedures can be created by digitalizing legacy maintenance guides and checklists and centralizing all maintenance-related procedures using a single solution. Moreover, managers can schedule and manage upcoming maintenance tasks, review past tasks, and create reliable records to track the condition of machines or equipment.

Frontline workers can access all sorts of instructions using mobile devices and wearables, but also create alerts and trigger notifications to inform managers and operators of any urgent issues.

Digital maintenance procedures can also be used for relevant use cases such as visual remote assistance. In practical terms, this means that operators can directly contact experts to help them conduct complex procedures and quickly resolve any technical issue.

Benefits

A Changeover process describes the stage of changing a production set-up, line, or machine to suit a specific product. Changeovers are crucial to ensure that the production line is prepared for the upcoming product and that there are no setbacks during production.

Paperless Changeover

Much like the two procedures described above, digital changeover procedures are the result of process digitalization and augmentation using AR. In essence, this means that frontline workers can access all instructions related to changeover procedures using a smartphone, tablet, or wearable to support their execution.

This is particularly relevant since changeover procedures are often performed by the most experienced workers on shop floors. Paperless changeovers are particularly important for use cases related to training and skills management as they can help ensure that more workers can perform these tasks and that fewer resources and time are put into training.

In addition, to optimize this procedure, businesses can require execution evidence (such as photos or videos) to ensure that tasks have actually been conducted. This can also be achieved by introducing augmented checklists that help workers follow instructions more closely and remain safe at all times.

Benefits

The LOTO process is a safety procedure aimed at ensuring that potentially hazardous equipment is properly shut off and won’t unexpectedly start up and that any energy source or chemical element is isolated.?The lockout/Tagout process is one of the most relevant safety procedures on shop floors as it neutralizes equipment presenting a danger of injury or death to workers.

Paperless Loto

Digital Loto procedures rely on digital work instructions and augmented reality-based checklists that can only be accessed with specific authorization from managers and other top hierarchical figures. This helps ensure that Loto procedures are correctly executed and that no workers are put at risk.

Moreover, it is possible to create customized inputs, such as different response fields, the introduction of QR codes, individual digital signatures, and execution evidence. As a result, workers will be notified in real time when a process must be carried out.

At the same time, task management is improved as managers can track tasks in real-time and review different workloads and other analytics.

Benefits

Part Picking is the backbone of any manufacturing or industrial operation. In essence, this involves locating, picking, and transporting items or materials which are required for the production of products. Part picking can take place across several locations on a shop floor and is essential to ensure that production rolls out according to plan.

Paperless Part Picking

In industry 4.0, the part-picking process can be efficiently optimized. Through the incorporation of different technologies, the digitization of instructions and inventory, and the integration of picking orders, it is possible to transform picking operations and adapt them to the new age of digital tasks.

In essence, this can be done by digitizing instructions, all inventory records, and picking order systems. Paperless part picking has a direct impact on knowledge management as it centralizes relevant information. This allows workers to be notified in real-time once a part is required without the need to consult physical orders. Instead, workers can use headsets or smart glasses to access picking orders and enjoy a hands-free experience while locating and preparing the required parts.

This procedure can be further improved through the introduction of physical clues (such as QR codes) to help identify specific locations and items.

Benefits

Learn more

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