Using COALA Solution
Diversey expects that the COALA solution will allow production line operators to request advices, explanations, and other information via the digital assistant running on a mobile device during the changeover (T3.4). Digital assistant will guide workers towards optimum configuration of the production line for each product and formulation (T3.2). The optimal production speed would be also considered by external factors, such as variation of bottle quality or ambient temperature at the production site. The cognitive advisor will help eliminating the fine tuning after reconfiguration of the production lines. Using COALA will reduce the change over time, time pressure caused by downtime, and lessen the cognitive workload of workers in solving unpredictable complex production line management tasks (T5.2).
Scenario 2: Training of Production Line Managers
Training product line managers is essential for the reliable operation of production facilities at Diversey. This training involves an understanding of the production machines, safety training, standard work instructions, and guidance from experienced operators. When a novice worker starts to operate a production line an experienced production line manager is provided as a supervisor.
Baseline. Diversey is spending approximately 4000-4500 hours on training its personnel per year only at its Italian site in Bagnolo. Extensive training enables these workers to get a general picture on how production lines need to be operated, what are the safety regulations and what are the typical steps and challenges of production line reconfiguration and operation management. This training, however does not allow enable sharing of tacit knowledge of experts.
Using COALA Solution
To refine the current training methods applied at Diversey, COALA solution is expected to reduce the time of (re)training of product line managers. To achieve this goal COALA will:
· Capture, formalize and contextualize tacit knowledge of product line managers about setup, reconfiguration, running, and maintenance of production lines for producing a given product. Experienced workers built up extensive experience with configuration and running of production lines, this knowledge is only partially captured and documented. Digital intelligent assistant will be used to capture the best practices for reconfiguring and running a production line (T3.1).
· Transfer tacit knowledge of product line managers to inexperienced co-workers (T3.2). Training of production line managers involves learning on the job activities and training onsite. DIA will be used to provide instructions on the site and in situ (T5.2).
· Standardize tacit knowledge of multiple experienced operators of the same production line. A production line is typically managed by multiple operators in different shifts. The best practices of running a production line according to different operators may differ. Diversey aims to standardize the best practices collection during training and during production with the support of DIA (T7.4).