HEINEKEN measures their operational efficiency with a metric known as Operational Performance Indicators. The purpose of OPI is to create a standard measurement for production line performance - a ratio between theoretical production time and the actual effective working time in any production environment.
Through the reduction of downtime and changeover times, HEINEKEN has increased their OPI significantly.
How was this accomplished? The simplicity and clarity of SwipeGuide’s digital work instructions allow for significantly more efficient product changeovers - (or the process of switching components and machine parts to accomplish different tasks in a production line).
An increase in OPI translates to huge cost savings for HEINEKEN. Not only in the hourly rate of operating machines and employee overtime, but also in the increase of production capacity and throughput.
Extract losses, the loss of product due to a defect or production error, have also been reduced dramatically. The increased availability of knowledge and increased First-Time-Right means fewer mistakes made by frontline employees and less waste for the brewery.
FTR stands for First Time Right, and is tied directly to error reduction. HEINEKEN uses this metric to ensure that processes in the brewery are performed correctly, the first time. When FTR increases, it means that employees are spending less time correcting mistakes and are producing higher-quality products at a faster rate.
We’ve accomplished this by making sure that machine operators have the correct knowledge in the moment of need. Rather than doing “the best they can,” they’re always guided to execute the process on a mobile device.
With SwipeGuide, FTR rates at HEINEKEN have soared. This represents significantly less waste of raw and packaging materials, a significant reduction in defects, and improved product quality.
HEINEKEN uses a methodology known as 5S to qualify and standardize hygiene practices, workspace cleanliness, and the efficiency of work on the shop floor. Since implementing SwipeGuide, 5S scores around the world have increased due to better access to work instructions, standard operating procedures, and hygiene best practices.
Cleaning Inspection Lubrication and Tightening is a crucial process used to ensure the success of regular machine maintenance. CILT standards focus on the cleaning, lubrication, and inspection of critical points on the factory floor. Great instructions help employees execute these tasks with less hesitation and frustration, and with greater accuracy by clearly outlining the individual steps. The minimalist and highly visual design of the platform also encourages on-the-job learning that lasts longer than traditional classroom training.
With SwipeGuide, HEINEKEN has seen the execution of CILT improve steadily. This means their machines run more efficiently and with fewer expensive failures and instances of unplanned downtime.
Coaching and Training.
One of the most innovative applications of the SwipeGuide platform at HEINEKEN has been the implementation of daily coaching sessions and One Point Lessons, facilitated by SwipeGuide’s intuitive step-by-step interface. Employees simply scan a QR code and receive important lessons on working safer, smarter, and more efficiently.