What are we talking about when we refer to self-monitoring?
Within the context of quality management, self-monitoring is a process integrated in the manufacturing line itself, which is essential to achieve and guarantee the preset quality standards. However, the most fundamental question arises.
What is self-monitoring?
A self-check is a process in which production operators have the responsibility to perform checks on certain characteristics. These personnel are linked to the production department and not to the quality department.
What is usually controlled in the self-monitoring are, mainly:
- Noticeable defects in the products or components at the end of the line
- The location of these defects
- Verification of product traceability
- Compliance with product manufacturing specifications
- Process variables
Where is the operator who performs self-checks located?
The workstation is usually a location where there is a terminal that serves different machines or terminals installed in the manufacturing line itself.
How often are self-monitoring performed?
Self-monitoring is performed on a frequency basis. The frequency is established in the Control Plan of the product. Normally, this frequency is established by time units, for example, every 2 hours, or by units produced.
What is the profile of the person who usually performs self-monitoring?
The profile of this person is usually someone with the ability to multi-task, as he/she has to be aware of multiple inputs of information that can determine that the product meets the preset requirements. These tasks can be such as:
- Loading raw materials
- Ensuring production timing and being part of product handling or assembly
- Report the status of semi-finished products through self-monitoring.
- Immediate corrective actions
- Visual verifications
They are usually personnel subject to certain rotation, which leads to a level of involvement that is often not as high as expected.
Why is it a challenge to tackle the digitization of self-monitoring?
Perceptual imposition of more work
The use of digital tools by operators is perceived as an imposition of more work, which generates greater resistance to change. This fact is fundamental to take this process as a challenge in which it is essential to analyze and dissect the causes why workers are reluctant to take to share responsibilities in a process of digitization of these self-controls. It is incredible the level of excuses given for not carrying them out in a society accustomed to handling a cell phone with much more complex functions on a daily basis.
Function conceived as the main function
First of all, we have mentioned above that the main function of the worker who is going to carry out the self-control is to produce. This conception is very much assimilated by this same worker and it is necessary to remember it.
Initial stage
Bearing in mind that the initial stage of all digital implementation projects requires some adaptation time and appropriate training, this can lead to a much stronger perception that the employee sees the digitization of his or her self-monitoring as an obstacle rather than a certain advantage at this particular stage of the project.
Multitasking profile
In addition, due to the multitasking profile and the inherent demands of meeting an established cycle time, this worker is often overloaded, making the use of digital tools an even greater challenge.
Perception of control
Those who work more directly with the manufacturing line may also perceive that they are being monitored at all times, which can be a source of pressure and a major contributor to reluctance to use digital tools.
Why digitize self-monitoring?
Having enumerated all the problems of the workers in charge of executing the implementation of the self-checks, why so much trouble in implementing digitization? Here are the advantages of making this type of decision.
Visibility of the status of essential characteristics
Digitizing self-monitoring means removing the blindfold for quality managers in terms of monitoring the status of product quality characteristics in real time.
Centralized data
This centralization of data, available and visible at all times, makes it easy for quality managers to act as quickly as possible and at the place where any anomaly has been detected, while minimizing the costs associated with production. The contingency costs that this possibility offered by the digitalization of self-monitoring is unquantifiable.
For example, if the digital system triggers an alarm because a part of the product has been damaged more than five times in a self-check at a certain frequency, the quality manager can quickly alert the production line to stop production for a moment and check for a possible miscalibration of the tooling that could lead to that particular part of the product being damaged. Kapture.io also offers the possibility to configure this type of alarms. This would be an example of a correction made just in time from invaluable information that has been obtained thanks to this digital system.
Reliable data
On the other hand, a paper-based reporting system for these self-monitoring data implies that it will implicitly require the transfer of all these data to a computer database, either with Microsoft Excel or through a specific ERP. This extra work entails a waste of time and money, since usually an effective staff is hired to perform this task exclusively.
Statistical control
Having statistical analyses that are constantly refreshed gives us a clear picture of how the production line is doing at any given moment. This means that we are not blind; we always know how things are going and we can make decisions based on current data, making sure that everything is running smoothly and quickly solving any problems that arise. In Kapture.io there is the possibility of incorporating analysis through Pareto charts, Gauss charts, etc.
Control panels and indicators
Finally, the availability of control panels where managers can visualize all the parameters of interest, as well as the KPI’s they consider appropriate in a quick and intuitive way, consolidates as an added value that could not be obtained through old methods such as the use of paper. With Kapture.io it would also be possible to display a Dashboard made with specialized programs such as Microsoft Power BI.
How should the digitization process of a self-monitoring system be carried out?
Having enumerated the intrinsic difficulties of the workers in charge of executing the self-checks, it is of superlative importance to design an interface that is as simple and user-friendly as possible. The operator must have the perception that things are being made easier with this type of action.
Maximum visibility
The sense of sight shows an ability to quickly process patterns, colors, shapes and visual details. Visual communication, therefore, is fundamental to a proper digitization process, so the elements that are part of the interface must be highly visual, as exemplified by the graphical elements of Kapture.io.
Few interactions
Operators should do as little as possible to perform self-monitoring because, as mentioned above, they are under a lot of pressure to meet the production requirements determined by the cycle time.
Avoiding errors
It is also important that certain parameters such as color, name, or reference are carried out through elements with closed options such as drop-down lists and avoid the use of imputation through free text to avoid unnecessary errors that may impair the data processing and penalize the time required to carry out the self-checking. Kapture.io offers the possibility to create drop-down lists and limit text formats to a specific nomenclature that helps to avoid operator imputation errors.
Access to documentation
Operators need to have access to documentation at hand within their digital self-monitoring system. In addition, one of the advantages of the digital format is to avoid that documentation can be misplaced if it is in paper format and easily updated. Each control guideline can be associated to the required documentation with another of the functionalities available in Kapture.io.
Involve operators in the design of controls.
Operators should be involved in the project as early as possible so that they can also share responsibilities in the implementation of the project and thus feel more important in the process.
It should also be noted that the operators must be listened to during this phase of the project. It is normal that adjustments are made, in part, also thanks to their feedback. Because of this, it is advisable to first pilot test part of the production line before implementing it massively throughout the plant.
The digitization of self-monitoring has revolutionized the way companies manage their operations. By digitizing these controls, we get more accurate, real-time data that is critical to making informed decisions. Instead of relying on manual systems that can be subject to human error or delays, we now have a reliable source that tells us exactly what is happening at any given moment.
But while digitization provides these advantages, it is crucial to think about those who will interact directly with these tools: the operators. If we design complicated or non-intuitive interfaces, operators are likely to find it difficult to adapt or, worse, reject their use. By putting operators at the center of the design and making sure the screens are user-friendly and easy to use, we not only make their job easier, but also ensure faster and more efficient adoption of the tool. This combination of accurate data and a tool that operators want and can use effectively is the key to implementing a successful self-monitoring system.
And for this digitization effort to be complete, it is also necessary to review the tools we use on a daily basis. Betting on solutions that go beyond simple spreadsheets is key to achieve a real and sustainable change in the plant. Discover in our next article why Excel is not the best option when it comes to digitizing quality processes.
