Smarter Week

How to automate it

How to automate “wait for a supervisor, maintenance or materials when the line stops”

Here are 2 ways to spend less time on this, best first. Each comes with steps you can follow today.

30 min
typically, every day
35%
of the time can be automated
Some setup
to set up

Fix 1 of 2

AutomationBest fix

Use a digital andon that calls the right person automatically

A button or tablet at the line sends the alert straight to the right person's phone or watch (maintenance, materials, quality) and escalates if nobody responds. Less waiting and walking to find help.

Typically saves about 40% of the time4 h to set up
  1. 1List the reasons the line calls for help.
  2. 2Set who gets each type of call and how long before it escalates.
  3. 3Set up a digital andon in your MES or connected-worker app, or a simple Power Automate or Teams alert.
  4. 4Track response times weekly and fix the slow ones.

Tools: Tulip, Poka, Augmentir, SafetyCulture or Microsoft Power Apps · Your MES · Microsoft Teams or Power Automate

Fix 2 of 2

Process fix

Set up two-bin kanban at the line for common materials

When the first bin empties it goes back to be refilled while the line uses the second. Materials arrive before they run out, and nobody has to go chasing.

Typically saves about 45% of the time4 h to set up
  1. 1Pick the materials that run short most often.
  2. 2Size two bins for each, so one bin covers the refill time.
  3. 3Agree the refill route and times with the warehouse or water spider.
  4. 4Review shortages weekly and resize bins that still run out.

Tools: Bins and cards · Your ERP or WMS e-kanban

Who does this task

Roles in our library that list this as one of their common tasks. Each guide covers the rest of that role’s week.

Machine operator / line worker

HourLeak · the 8-minute work audit

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Other common tasks for Machine operators / line workers