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THE BUSINESS PROBLEM
In theory, every defect or production abnormality is an opportunity to learn and improve performance.
In practice, the gap between when the problem occurs and when root cause analysis is complete means that by the time your trainers and quality engineers are ready to talk to the operators, the operators themselves have long since moved on. As a result, it becomes difficult to move the needle on the defect rate.
Here’s how one auto tier one used Drishti to slash the time between problem and resolution — and halved their defect rate in the process.
WHAT’S THE CURRENT METHODOLOGY?
Without Drishti, when a defect occurs, the root cause is usually often uncertain. Quality engineers are engaged to investigate, often following prescribed time-consuming methodologies. A report may take days or weeks to develop.
Countermeasures will often include training, either for the entire team or for individual operators. But by the time the training happens, the incident in question may have disappeared from the individual operator’s memory, and therefore the training will be much less effective, and the defect rate will persist.
HOW DRISHTI HELPS
This manufacturer deployed Drishti's solutions at each station on the line. Drishti can provide complete video traceability for station activities and also measure the cycle time of each unit at each station.
These two Drishti products are used together in a training workflow to slash the time between when a defect is committed and when the operator receives training. Here’s how it works.
STEP ONE: Perform quick root cause analysis
When a defect or abnormality is discovered, this customer uses Drishti to review video of the assembly activities. Its YouTube-like interface lets them quickly filter video based on line, station, time, product, etc., to pull video of what went wrong. Thanks to Drishti, each cycle has already been isolated and measured.
STEP TWO: Assembling training videos
The supervisor or engineer tags or annotates the video clips to organize them in a logical way to support their training needs. (If the root cause goes beyond operator training — a materials flow or product design issue, for example — the video will be shared with colleagues so they rapidly address the problem.)
STEP THREE: Training the operators
This customer prefers 1-on-1 training, with supervisors and operators reviewing the video and discussing together. But there are many different training models that Drishti supports:
To support these learning scenarios, Drishti offers a number of different ways to use the videos:
This particular customer performs these steps within minutes or hours of a line abnormality, depending on the nature of the issue.
KPIs AND SUCCESS METRICS
This manufacturer has around ten lines producing similar goods. Drishti was initially installed on just one of them, providing an opportunity to benchmark the efficacy of using video to quickly respond to defects with video while the incident is still fresh on the operator’s mind.
In the six months prior to installing Drishti, this customer had 26 in-process defects. In the six months following Drishti’s installation, the number of defects was just 13 for this line—while the lines without Drishti showed no such improvement.
Read more about Drishti's solutions.
