Cyclical celebrations - Case study
InnerWeb system
Growth-focused companies, for which it is important to improve the company’s efficiency and implement cost-optimizing solutions, need constant process control to be able to react to changes in time and intervene in a timely manner.
Challenge
Our client Grupa Azoty S.A., which is a leader in the fertilizer-chemical industry across Europe, conducts up to hundreds of hazardous jobs every day. Every day, shift masters make 2 cyclic rounds each in explosive areas where there is a very high risk of accidents.
When the fault is not found in time, then it is necessary to organize the arrival of specialized companies that are able to fix the failure. This generates high costs and affects the downtime of the work.
Need to make 2 rounds per shift
High risk of machine breakdowns
High cost of machine downtime and repair
Process
In response to the company’s struggles, we installed 10 radio beacons in a specific area of the hall. We conducted a training session with the masters responsible for the rounds, which took only 20 minutes. On the very first day, the trained team was ready to work with the InnerWeb application and started implementing the rounds in the new automated formula.
Solution
Taking into account the need to streamline work organization, the InnerWeb application effectively automates the process of making rounds.
It makes communication about reported faults and failures much easier and faster. When the master, while making his rounds, notices a defect on the installation, remaining in the same place, he can report the problem through the application to the designated team. This definitely affects the response time, thus minimizing the amount of potential costs arising in the situation of machine downtime and repair.
The ability to immediately report faults and failures of a particular machine is done with the attachment of photo documentation. Without the need to move around and make phone calls, detailed information can be sent immediately to selected people. This also reduces the duration of any downtime and makes communication more efficient and effective.
In a situation where an employee needs to obtain the technical documentation of a particular piece of equipment, all he has to do is scan the QR code stuck on it or be near it. He will then obtain full information about that machine. This feature can streamline and speed up the rounds, as well as the process of reporting malfunctions and calling in repair specialists, who can access the technical data and history of the machine at a glance.
What’s more, the system sets off an alarm if a workaround is missed, so the risk of missing this important process during the day is negligible.
The application also contains all documents, regarding machines and equipment. Standing at a particular piece of equipment, you can get all the information about it, without moving around and laboriously searching for it, which saves a lot of time.
These application functionalities significantly speed up and improve the transmission of messages, as well as the response time to
them, which finally reduces the duration of any downtime. This minimizes the risk of failures and minimizes the costs that downtime and repairs generate.
Benefits
- Reduced risk of machine breakdowns
- Reducing the time of possible downtime
- Reduction of costs generated by repairs and downtime
- Saving time in communicating breakdowns and acquiring machine data
- Automatic recording and collection of data useful for calculating profitability or efficiency of machines.