- Schaeffler Group
- Headquarter location: Herzogenaurach, Germany
- 87,900 employees worldwide
- Divisions / Business Units:
- Automotive (e.g. engine systems, transmission, chassis)
- Industrial (e.g. wind turbines, linear technology)
The FACTS4WORKERS solution at Schaeffler
Context of use
- Learning support for test rig operators (SCA1)
- Paperless information management for assembly workers (SCA2)
- Transition to a value stream oriented production
- Integration of quality assurance (QA) in the value stream
- Just in time production (smaller batch size, higher frequency of setups)
- High number of required documents (QM system)
- Different information sources (ring-binder/ SAP / other software systems)
- Fight for talents (be attractive for new employees)
Room for improvement
- Develop QA employees as service providers
- Improve knowledge exchange and enable training on the job for all employees by using a comprehensive data base
- Easy access and management of information (e.g. shop floor management, quality documentation )
- Harmonize information sources / data medium
- Optimize shift handover by implementing a digital logbook/ journal
- Prevent information loss/ reduce down times
- Increase documentation quality
- Workplace attractiveness & worker satisfaction
- Empowered employees
- Increase productivity
- Roll-out FACTS4WORKERS within Schaeffler Group (74 plants worldwide)
The FACTS4WORKERS solution
Field of application
- Testing of rolling bearings
- Production of engine components
SCA is an automotive and industrial supplier with a worldwide network of manufacturing locations and research & development facilities. In Schweinfurt, in addition to the production, there is also the competence center for testing rolling bearings. The tests require the highest level of precision and experience and are carried out at several production sites worldwide. In Ingolstadt various engine components are produced. Recently the plant has changed its production process paradigm from "workshop series production" to a modern "value stream production".
Overview of activities in the department
The activity overview provides an overview of all activities in a department. The list can be displayed for one day or whole month. In this list, the creator displays his activity at the corresponding plant, the date, and the activity.
The monthly view of activities in a department provides a chronological overview of the activities to date, e.g. regarding a machine. This allows employees to find information with little effort and to make informed decisions. In addition to the actual information the worker will find the originator and thus a contact possibility - even if they work on different shifts.
The employees themselves can write directly entries so that the corresponding activities can be documented directly on the machine or in the group room. In addition to normal entries, messages can also be sent to the following shift, so direct communication with colleagues working at different times is possible.Semi-automatic relevant activity logs of machines or processes (for example, maintenance work) are also entered directly into the shift register.
SCA 2 – Integrated documentation of the shift
At the end of the shift, the tool adjuster documents important events in a handwritten book, and fills a series of further paper-based forms.
In this process, there are many redundant information to maintain, since the forms are only partly matched to one another. In addition, it is not possible to add photos or digital documents, so more needs to be described.
The paper-based documentation leads to the problem that it can not be searched efficiently and that it is site-bound, that is, the colleague from the office who wants to take a look must first find the shift book and then leaf through.
With the digital shiftbook 2.0, colleagues can document important incidents already during the shift, for which events are documented semi-automatic, e.g. after maintenance work, and only need to be commented in case of need.
The photo function of the tablet allows not only text and audio messages but also images to be directly documented. This saves a lot of paperwork and makes it tangible for the other colleagues.
Due to the integration of the forms and shift log entries, these must no longer be maintained redundantly. In addition, the relevant information is available to all relevant employees, regardless of time or place.
SCA 2 – Mobile deployment planning and preparation
Shortly before the start of the shift, team leader Jürgen has to draw up the shift schedule. However, he first needs to gather information about key production figures and attendance lists with all the sick certificates and "on vacation" notices before he assigns the employees to the machines they will be responsible for. He does this by putting prefabricated cards in the respective pockets on the board in his office. Jürgen has to consider special situations, for example when workers from his team are delegated to other assembly lines due to production bottlenecks or vice versa.
Such situations must be coordinated with other team leaders as well as the product manager. After the schedule is finalised, operators and tool setters come to the team leader’s office before starting their shift to get the information about their daily schedule.
Shortly before the start of the shift, team leader Jürgen assigns the employees to the machines they will be responsible for by dragging the icon on the tablet into the corresponding field. He can choose and allocate statuses like "workplace not staffed" if some workers take sick days, are on vacation or have been delegated to other assembly lines. If additional staff is called for in the assembly line that falls under his responsibility, he can mark this workplace as “multiple staffed”. The shift plan will appear on a central screen on the shop floor, so that operators and tool setters can check today’s schedule directly and start working at their machines. All possible updates during the shift also appear onscreen.
Additionally the digital workforce management allows faster and more efficient ways of communicating with the HR office. Information on who was working at which machine is stored centrally in the system. This leverages transparency and makes it easier to find out whom to address if problems occur that correspond with past incidents.
Improvement with regard to influencing factors.