Production Company Registering employees at a workstation

1 Situation

In a car plant factory, over 2400 employees work across 3 shifts over 800 work stations. The work is performed according to carefully outlined processes...

Viac info

Situation

In a car plant factory, over 2400 employees work across 3 shifts over 800 work stations. The work is performed according to carefully outlined processes. Given the variety of the work, the workload for an operator is different at every workstation. The production system cannot clearly identify an operator, which results in the following risks:

Work overload for the operator

  • Risk of becoming burned out

Impossible to track time spent at an especially risky workstation

  • Bonus for working at a risky workstation
  • Statutory compensation

Impossible to effectively identify the cause of a problem, leading to the lower effectiveness and lower quality of the output

  • Identification of a system flaw
  • Need to retrain the operator

Impossible to control whether the operator has the necessary skills

  • The operator was not trained

If a particular work task requires specific training, it is impossible to check

  • Measuring the static charge of a given operator (ESD)

2 OBJECTIVES

  • to prevent operators from being overworked
  • to track the exact time spent at a risky workstation
  • to identify early a problem in the work process
  • to prevent the operator from working at a workstation without the necessary qualification and training
  • to prevent the operator from working at a workstation if he/she didn’t pass the necessary tests and controls (e.g. ESD control)

3 Solution

The Contal Timetec Production system was chosen as the solution. This system is used for registering employees at various workstations and would be linked with the systems that are already in use in the factory...

Viac info

Solution

The Contal Timetec Production system was chosen as the solution. This system is used for registering employees at various workstations and would be linked with the systems that are already in use in the factory:

  • Personal system
  • Health and Safety Regulation System (rotation of workstations for individual operators)
  • MES system
  • System for quality management
  • Attendance system

During the preparations of the implementation, the customer had an independent study delivered where individual workstations were analyzed. Each workstation was given a workload index along with a cumulative limit that must not be exceeded by an operator. An automatic system of scheduling rotations based on the recorded data ensures this.

Given the aforementioned, all workstations were equipped with a card reader that measures the exact time from inserting the card till ejecting the card. At some spots, terminals showing the cycles of rotation where installed. Finally, large TV screens showing how individual workstations are occupied or other information were installed.

1 Choice of appropriate identification card

Since the company was using the Mifare cards, we used them for registering the operators at their workstations. As an identifier of the employee we used a number chain saved in the memory of the card that can be read from the card.

2 Identification of workstations and spots for showing system information

We identified 805 workstations, 50 places for showing information terminals and 20 places for information screens

3 Equipping the workstations with the respective products

All workstations were equipped with CCR-Slot102 card readers. Every operator will insert their card here after coming to their workstation. For workstations near the production line, we installed CCR-SD Terminals for showing the cycles of rotation of the operators. The information will be shown to the operator after tapping the identification card. Lastly, we installed the information screens.

4 Creation and configuration of databases, installation of software application

Two MS SQL databases were created on the database server:

Configuration Database

  • Place for saving the system configuration

Statistical Database

  • Collecting of transactions from the card readers and terminals
  • Link to the following databases:
    • Personal system
    • Health and Safety Regulation System (BOZP)
    • MES System
    • Quality Management System
    • Attendance System

The application for the configuration of the system was installed on the application server.

5 Configuration of the system

Workstations were created in the system and were assigned the required levels of qualification as well as workload indices. The information terminals are linked to the Health and Safety Regulation System and show the rotations of individual positions for each operator. The information screens would show the occupation of individual workstations as well as other information related to work processes.

4 CONTRIBUTION

  • Elimination of causes for burnout
  • Scheduling of work shifts made easier
  • Increased effectiveness of work processes
  • Increased quality of products
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