Scenario:
The beverage company faces frequent stoppages, which lead to production loss and variation in the bottle quantity (overfilled or underfilled), which leads to increased production waste and customer complaints.
To eliminate this problem and customer complaints, the operation improvements team approached line operators and maintenance technicians and discussed the problems and listed the causes, such as
1. The operator frequently identified that jams were caused by worn guide rails and sensor misalignment in the packaging line.
2. By listing out the machine health check parameters, they found that many bearings in the conveyor section are noisy and vibrating, which may lead to breakdown, and some of the filler nozzles are also clogged because the nozzles get dribbling and vibrating after a certain cycle of usage, which causes the sticky residue in the filling nozzle.
3. Maintenance technicians suggest increasing the lubrication cycles for the specific area where the wear and tear parts are high and changing the filler nozzle before it starts dribbling and servicing it in a timely manner.
From the suggestions from the operators and technicians, they decided to implement the action points in the production line as
1. Major problems are caused because of the minor issues in the production line, so the operator gets well trained in machine maintenance, such as routine machine checklists, cleaning, and lubrication, and any minor alignment can be done by the line operators. This will reduce the downtime, and by training them, it can be fixed without maintenance team interference for the minor issues that they face during running production.
2. Preventive maintenance and replacement will be the solution to address this issue by developing a schedule for proactive replacement for high-wear parts like conveyor bearings and filler nozzles before they fail, based on operator/technician recommendations.
3. Increase the frequency of regular sensor calibration and replace the faulty ones, which will eliminate the wastage and improve the productivity.
From this scenario, business excellence leverages the voice of the employee (operators and technicians) by getting feedback from them about the process issues, solutions to rectify the issues, and improvements to be done in the process to avoid the challenges in future operations.
Challenges hinder gathering actionable employee insights;
1. Fear of speaking up—in some cases, they don't trust their boss or feel sometimes their honesty could lead to negative consequences.
2. Continuous collection of data or feedback from employees, but not using it.
Strategies to overcome these challenges:
1. Build Trust: Use anonymous surveys or suggestion boxes so employees feel safe. When action is taken based on employee suggestion or input, reveal it to the employee and thank them; it will build employee confidence.
2. Regular Feedbacks on Action points: Once you get the feedback, assign someone to review and look into it and update the employee on a regular interval basis on what is being done with their feedback.