In the sector in which Alestis operates, the industrial manufacturing process, and more specifically, the requirements set by quality agencies and certifying bodies, require a sealed and signed documentary record that evidences the completion of each operation and certifies the conditions under which it was carried out. How can these operational flows be ensured, streamlined, and improved through digitization?
In this context, the volume of paper generated in the process is enormous, leading to high bureaucratic costs, management costs, loss of quality and traceability, and a waste of productive time that, in return, is solely dedicated to meeting these regulations.
But the problem is not only the documentation that needs to be generated, but also the documentation that needs to be consulted. How much time does each person spend searching for the applicable standard for a particular drawing or task? What risks exist that the version of the standard or document being consulted is the correct one? To address all the described scenarios, the designed project sets the following high-level objectives:
- Save management and quality costs by storing, processing, analyzing, and reporting the documentation generated during manufacturing.
- Obtain manufacturing information in real-time.
- Reduce the time spent on completing documentation.
- Minimize the possibility of error as much as possible when completing and consulting manufacturing documentation.
Core paperless system. Development of a software system that allows, on one hand, the digital, assisted, and personalized definition of all types of documents (and their versions) that need to be generated during the manufacturing process, providing multiple types of fields for this purpose; and, on the other hand, determining which operations each of the designed documents applies to. If each time a 'Drilling' operation is completed, it is necessary to indicate in a document which type of drill bit and which batch of sealant was used, the production manager can generate this document digitally and assign it to the 'Drilling' operation type.
Integration with the documentary system. If, in addition, there is a document management system that stores all the current manufacturing documents, plans, standards, manuals, etc., the paperless system integrates with it, providing the end user in real time and in digital form all the documentation, in its corresponding version, that applies to a specific work order or operation.
Production management. The two previous steps are finally incorporated into the end-user oriented production management system. Each time an operator, via a touch screen, executes or completes an operation, the system asks him/her to fill in the required documentation automatically, showing the form for this purpose. The system also autonomously and univocally registers the person who stamped the operation and registered the document (under a secret code), the date and exact time, and even the temperature and humidity conditions of the plant at that precise moment.
The application of paperless digital solutions drives increased efficiency and cost reduction, positively impacting the productivity of the manufacturing process and improving its quality and control processes.
With the implemented solution, the challenges and objectives set are achieved, improving key aspects of the production process and cross-functional areas within production management itself.
0 SECONDS... dedicated to document consolidation and traceability.
50% REDUCTION... of time spent on registration of manufacturing documents.
0 MINUTES... dedicated to the personal sealing of operations.
In the sector in which Alestis operates, the industrial manufacturing process, and more specifically, the requirements set by quality agencies and certifying bodies, require a sealed and signed documentary record that evidences the completion of each operation and certifies the conditions under which it was carried out. How can these operational flows be ensured, streamlined, and improved through digitization?
In this context, the volume of paper generated in the process is enormous, leading to high bureaucratic costs, management costs, loss of quality and traceability, and a waste of productive time that, in return, is solely dedicated to meeting these regulations.
But the problem is not only the documentation that needs to be generated, but also the documentation that needs to be consulted. How much time does each person spend searching for the applicable standard for a particular drawing or task? What risks exist that the version of the standard or document being consulted is the correct one? To address all the described scenarios, the designed project sets the following high-level objectives:
- Save management and quality costs by storing, processing, analyzing, and reporting the documentation generated during manufacturing.
- Obtain manufacturing information in real-time.
- Reduce the time spent on completing documentation.
- Minimize the possibility of error as much as possible when completing and consulting manufacturing documentation.
Core paperless system. Development of a software system that allows, on one hand, the digital, assisted, and personalized definition of all types of documents (and their versions) that need to be generated during the manufacturing process, providing multiple types of fields for this purpose; and, on the other hand, determining which operations each of the designed documents applies to. If each time a 'Drilling' operation is completed, it is necessary to indicate in a document which type of drill bit and which batch of sealant was used, the production manager can generate this document digitally and assign it to the 'Drilling' operation type.
Integration with the documentary system. If, in addition, there is a document management system that stores all the current manufacturing documents, plans, standards, manuals, etc., the paperless system integrates with it, providing the end user in real time and in digital form all the documentation, in its corresponding version, that applies to a specific work order or operation.
Production management. The two previous steps are finally incorporated into the end-user oriented production management system. Each time an operator, via a touch screen, executes or completes an operation, the system asks him/her to fill in the required documentation automatically, showing the form for this purpose. The system also autonomously and univocally registers the person who stamped the operation and registered the document (under a secret code), the date and exact time, and even the temperature and humidity conditions of the plant at that precise moment.
The application of paperless digital solutions drives increased efficiency and cost reduction, positively impacting the productivity of the manufacturing process and improving its quality and control processes.
With the implemented solution, the challenges and objectives set are achieved, improving key aspects of the production process and cross-functional areas within production management itself.
0 SECONDS... dedicated to document consolidation and traceability.
50% REDUCTION... of time spent on registration of manufacturing documents.
0 MINUTES... dedicated to the personal sealing of operations.