Comparison
DiGi instead of Excel and paper cards
Ten everyday situations on the floor. On the left, how it is today in many plants. On the right, how it looks in the system.
Paper and spreadsheet
DiGi system
When you learn something is wrong
Paper and spreadsheetThe next day, after retyping the cards into a spreadsheet. Or at a complaint.
DiGi systemAt the moment of measurement. The trend is visible before the result leaves the tolerance.
Entering results
Paper and spreadsheetThe operator reads the gauge, writes it down, someone retypes it. Every step is a chance for an error.
DiGi systemThe gauge sends the value at the press of a button. Nobody retypes anything.
Did the inspection happen
Paper and spreadsheetNobody knows. A card filled in "from memory" looks the same as an honest one.
DiGi systemThe system watches the inspection moment and counts how many were done out of those planned.
Downtime reasons
Paper and spreadsheetA shift report written afterwards. Every shift describes the same thing differently.
DiGi systemThe reason picked at the moment of the stop, from one dictionary for all shifts.
Piece count
Paper and spreadsheetThe counter copied from the machine at the end of the shift. Arguments about how many really came out.
DiGi systemPieces counted from the machine cycle, even when nobody is logged in.
The auditor asks about a measurement from three months ago
Paper and spreadsheetSearching binders. No information about what it was measured with and against which plan version.
DiGi systemA few seconds. Who, when, with what, on which cavity and what the specification was at the time.
A control plan change
Paper and spreadsheetA new printout, swapping sheets at workstations, old versions circulating on the floor.
DiGi systemThe change is visible on the tablet right away. Every measurement remembers which plan version and tolerance it was taken against.
Complaint: what this batch was made from
Paper and spreadsheetThe batch number from the label, then delivery documents, the shift notebook and the operator's memory. An answer after a few days.
DiGi systemYou open the batch and see the raw material batches, machine, shift, operator and inspection results. An answer the same day, with evidence.
A report for management
Paper and spreadsheetSomeone assembles it on Monday from several spreadsheets. Every week in a different layout.
DiGi systemThe shift and daily report arrives by e-mail on its own, in the same layout. A new breakdown takes a minute.
Analysis
Paper and spreadsheetA spreadsheet done by hand once a month by the one person who knows how it works.
DiGi systemControl charts, Cpk, defect Pareto and the loss waterfall are calculated automatically, continuously.
Honestly
- Excel is good for a one-off analysis. The problem starts when it becomes the data collection system.
- Paper is cheap at the start. The cost shows up later: in retyping, in errors and in having no answer to the customer's question.
- The system will not fix the process for people. It shows where to look and makes sure agreed actions get closed.
- The first weeks are more work, not less: control plans and cause and defect dictionaries have to be entered. We do it together, on one workstation, before you add more.
- One machine, one operator and a customer who never asks for evidence? Stay with the spreadsheet. Come back when the second workstation or the first audit appears.
Start with one workstation
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Piotr will help you pick the solution that fits your production processes.
Phone: (+48) 668 211 736
Email: digismartcontrol@gmail.com