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Webinar: Why do improvement programs often fail

Improvement programs have become common in our industry, but why is it that these programs fail most of the time? The answer is simple and so is the cure.
In this webinar Mark Satink of Wonderware Benelux and Hein Winkelaar of PSTAMP show the pitfalls and the possibilities to make it a success story.

“We must learn to make the switch from reactive to proactive acting,” Hein Winkelaar explains. The cyclic Plan, Do, Check, Act from the fifties and later on TPM, LEAN, Agile etc. are all depicted by Hein. “All these programs can work, if the procedures are safeguarded and otherwise it is a waste of effort.”

The strength of knowledge and experience on the floor

The goal of an improvement program is to assure that every employee does its utmost to continuously improve all operating conditions of the (production) system. “ Every employee means that you have to get everyone involved. Too often important stakeholders on the work floor are being forgotten and that is a major shortcoming. These underestimated people are your ears and eyes and have the most valuable sensors of your company. ”

Mark Satink: “In the webinar of 1 April 2020 we discussed how to unlock, use and analyze historical data. We live in a digital era, but a lot of this data is still being collected manually. Paper checklists function well, if you have the full discipline to do every inspection round consistently right and in time. That is often not the reality and unfortunately the paper is not able to shout and attend you that you have to fill it out. ”

Furthermore, people often forget some relevant steps after a while. “Plan / Do means that the plan is being adjusted constantly and this way you will never achieve your initial goals. The switchover to proactivity can be made by a change of focus to Check / Act. This helps to prevent problems and failures and that is a condition for a successful improvement cycle. ” A real-life example shows That Hein and his team were printable to Improve the OEE of a business-critical pump As They started working proactively. “We made progress straight from the start and then I realized that I had to safeguard this to make sure that this was not just a momentary success.”

Who was Where, observed What and When?

“With CheckStamp © we offer a low-threshold, easy to use and easy to implement solution that covers these four W’s. Wonderware also offers more extensive solutions like IntelaTrac. ”

Every (inspecting) employee gets a personal pass (Who), all the assets get a barcode (Where) and with a scanner every asset is checked and the findings are listed (What) and the time is noted automatically (When). “This is not a replacement of the existing procedures, it is the necessary step that assures that all the paper inspection rounds are well-executed, in time and exactly as prescribed.”

It sounds easy and Mark and Hein prove that it is easy. They both make an inspection round and the collected information is stored in a database – via the docking station – and made available for everyone in an understandable, readable report (in Excel).

“We entered into a partnership with Wonderware Benelux because they have a great portfolio of smart products that supplement our products. And they have a covering network of system integrators and we together can make this a great success story. This is the easiest step forward to structural improvement and it is operational within a day! ”

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