Registration & App

The first step, and perhaps the most important step, with continuous improvement is collecting information and identifying all the disruptions and incidents. After all, first you need to know what goes wrong, before being able to improve. Correct input is essential for correct output. Therefore it is important that the registration procedure is as simple as possible. It also increases the report willingness. It concerns registration of all events in production and QHSE incidents. Often people think of technical failures, like damaged parts or machines with suboptimal line speed. However, most losses are because of bad internal logistics and communications. Think of no or wrong supply of materials, no optimal set up of the production process, or bad instructions.

Registering events is done in a "failure tree". We have years of knowledge and experience in (production) processes and we will, together with the customer, comprehensively analyze the them and create a proper failure tree.

Failure tree

The failure tree is very flexible and dynamic. You can register anything you think is important. For production optimization you can insert the whole production process. If you are dealing with the Food & Drug Administration (FDA) you can include Food Safety or Animal Well-being high up in the tree. You want to report safety issues and incidents? Include all QHSE aspects. See the picture for an example of a failure tree set up. The tree is easily adjustable and grows with the needs of the company.

The registration

Registration of events can be done in different ways. Manually by using a computer, directly next to a machine, at your office, or any other place. For quick and easy registration you can also use the app. You want to have automated registrations? We can connect the PLC of the machines to ProMISe or use sensors to register signals like: machine running, speed of machine, etc.

Note the starting and end time of an event for downtime measurement, add some pictures for more clarifaction, add some comments for detailed information and select the root cause in the failure tree including the used solution. ProMISe remembers all solutions. When the same or comparable failure occurs (for example a broken bearing on a different location) ProMISe will suggest a solution that is used before for the same failure. It is also possible to register the time an operator needed in total after the failure was already solved: "operator time". Production was able to resume already, but the operator could have had alot of hassle because of it. Concerned failure could have been very shortly and insignificant. However, an operator that has alot of hassle multiple times when such failures occur can be a reason to discuss that problem and to solve it.

The App

Even quicker and easier everyone can register an event using the ProMISe App on his/her mobile phone. Also provided with pictures. A pictures often tells more than words. Internet connection is not even required. Quite useful for operators on site or when one hastely needs to solve the failure and does not want to forget to register the downtime.

Machine connection

It is also possible to read out the PLC of the machine or extract information from sensors for more precise, automated registrations. Alarms of failures come in with start or end time. The unique tag codes correspond with a location/part in the failure tree. The operator only needs to verify the alarm or possibly adjust it.