Dozuki > Case Studies > Digitizing Processes with Dozuki Saves Thousands Per Hour for Leading Equipment Manufacturer

Digitizing Processes with Dozuki Saves Thousands Per Hour for Leading Equipment Manufacturer

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)
Sensors - Gas Sensors

Applicable Industries

Equipment & Machinery
Mining

Applicable Functions

Facility Management
Maintenance

Use Cases

Time Sensitive Networking
Virtual Training

Services

System Integration
Training

About The Customer

The customer is a leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines, and diesel-electric locomotives. With a history spanning almost 100 years, the company has established a strong presence in the equipment manufacturing space. Through its subsidiaries and dealers, the company markets and sells its products worldwide. The company was seeking to digitize and standardize its processes to minimize waste and control machine setups and changeovers. However, it faced challenges in achieving this goal due to limited existing documentation, difficulties in gathering and implementing frontline feedback, inconsistencies in production, competency gaps among employees, and safety concerns.

The Challenge

For nearly a century, a leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines, and diesel-electric locomotives has been striving to digitize and standardize its processes to minimize waste and control machine setups and changeovers. However, the company faced significant challenges in achieving this goal. The existing documentation was limited, making it difficult for frontline workers to share feedback to improve operations. The company was using Excel to create and store process information, which often contained over fifty pages of information that workers had to read and retain. This method also lacked the ability to gather and implement frontline feedback, leading to missed opportunities for operational improvements. The company also faced inconsistencies in production, competency gaps among employees due to job shadowing as a primary training method, and safety concerns. The introduction of new automation technology also posed a challenge as the company needed to ensure that standards were properly distributed to frontline operators.

The Solution

The company turned to Dozuki to address these challenges. Dozuki was initially piloted at one facility, and after seeing positive results, it was rolled out at other facilities. Dozuki allowed the company to rapidly create, digitize, and deploy standards in a format that all employees could easily understand. It also addressed the issue of unrestricted access to documentation, which had previously led to duplication, accidental deletion, and extra document handling. With Dozuki, operators could access content directly from the floor with a QR code scan, even in the extreme environment of the forge. This ensured that the right content was always in front of the operators, reducing mistakes and quality issues. Dozuki also provided a purpose-built document control system that allowed operations stakeholders to see the full list of process documentation that needed approval, enabling them to quickly update content and instantly distribute it to frontline operators. It also included a built-in audit trail to track all changes.

Operational Impact

The implementation of Dozuki brought about significant operational improvements for the company. It enabled the company to rapidly digitize and standardize its processes, making it easier for employees to understand and follow them. This led to a reduction in mistakes and quality issues. The unrestricted access to documentation was also addressed, preventing duplication, accidental deletion, and extra document handling. Operators could now access content directly from the floor, ensuring that they always had the right information at their fingertips. The document control system provided by Dozuki also streamlined the approval process for process changes, saving time and reducing confusion. Furthermore, the built-in audit trail provided a clear record of all changes, making it easy to revert them if necessary. Overall, the implementation of Dozuki significantly improved the company's operational efficiency and safety.

Quantitative Benefit

Dozuki implementation resulted in zero downtime for over three weeks straight, previously the process caused 2-8 hours of machine downtime 3 times per week.
$15,000 saved per hour due to reduced downtime.
75% reduction in revision time.