Whirlpool Slovakia
Location: Poprad since 1992
Function: Washing mashines production (top load and front load)
Production capacity: 2,4 mil. products per year (11 000 daily) in 2016
Employment: 1400
Member of Whirlpool Corporation, the biggest manufacturer of home appliances in the world.
Implemented products: ORS, TLS, OEE
Requirements
There are the most important system requirements for ensure the required level of production quality:
Checking levels of operators training with the possiblity of backup
Current skills matrix and abilities of work at individual work positions
Realtime overview of current situation in individual workpositions at workplace
Simple integration with existing production systems and software
Work process recording with possibility of reward system
Level of work difficulty on the base of indicators of quality, logistics, difficulty and safety
Background
Unauthorised operators work can slowdown the production or cause the errors in production. Products from Whirlpool company must have the world class quality, so there is need to remove unauthorised work and planning trainings for operators for ensure the required level of production quality.
The solution has a job to ensure:
Complicated shift making due to absence of employees and difficult filter in data overview of qualifications, certifications and competentions of employees
Backup overview in the higher fluctuation
Unauthorized time spent for the operator’s training on the workposition
Need to get more data for increase the quality of production and HR
What did the system implementation do?
The pilot project was realised at 2 production lines for production the top load washing machines with possiblity of monitoring 114 working positions. Every working position has implemented RFID reader with screen. The operator has to login with his access card on the work position before the work. Operator can see following statuses on the screen:
Authorized login (sufficiently trained)
Unauthorized login (insufficiently trained)
Backup possibilities
Ongoing training
Required training
Operators can realized very fast and easily, if they can work at the work position and what conditions are required.
HR managers have better overview for workpositions, trainings, data for salaries calculations due to shifts.
Operations and quality managers, project leaders and team leaders has the realtime overview at the work positions and the current login status.
The digital mirroring can monitor the production status in realtime, detect the low quality and identify the critical tasks. There is possiblity of quick setup of working shifts based on the current situation and trained employees.
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