Learning to read the line

Training courses for machine and system operators have long been a fixed feature of the KHS portfolio. Correct operation of machines is only one side of the coin, however; understanding their roles in the context of an entire line with its vast number of interdependent processes is the other. Goods and material flows, ongoing maintenance measures and cooperation between production personnel: these and various other factors influence the speed and effectiveness with which sources of disruption can be detected and remedied. 

Complex interaction

This is precisely where production line coaching comes into play, a new service from the Dortmund systems supplier. “Our lines integrate reliable machine processes that are exactly coordinated with one another to enable maximum performance,” says Pasqual Sturm, line optimization auditor at KHS. “Line coaching sensitizes production managers and shift supervisors to the various influences and sources of disruption prevalent in the production environment, allowing them to use their line as KHS intended: for maximum efficiency and permanent top performance.”
 

Essential details

New production lines, increasing demands for efficiency and resource conservation and employee fluctuation: these are just a few reasons why the level of know-how needed to operate customer lines in an optimum fashion can greatly vary. The many years of experience gathered by KHS’ line optimization experts show that a lack of detailed knowledge often results in lost time and a drop in line efficiency. Production line coaching ensures that customers develop an in-depth understanding of the processes surrounding their machines and the impact these have on line function.

The increasing use of digital monitoring systems can provide assistance here. “The information constantly captured by a data analysis system provides key indications of the state of the line,” emphasizes Roger Schwarz, line optimization auditor for KHS. “So that customers can exploit the efficiency of their line to the full, personnel must interpret this information correctly. This is the only way unplanned downtime can be avoided.”
 

In-depth understanding

Sturm explains how this works using the following example: “At the end of the line, the product conveyor doesn’t collect the full product pallets from the palletizer fast enough. The upstream packer therefore halts operations and reports a line stop. This message then has to be compared to the real events on the line to pinpoint the actual cause of error. This where operator machine expertise comes in – this decides how quickly the actual cause of the fault is found so that the line can carry on running smoothly.” A sound understanding of the dependencies and interactions within the entire production setup is thus essential here, Sturm believes.
 

Good for efficiency and the team

Production line coaching results in a genuine win/win situation: beverage producers increase their line efficiency and shorten the amount of downtime. At the same time, they invest in their personnel. For not only new employees benefit from extensive expert knowledge; experienced colleagues also refresh their know-how and supplement this with a more holistic perspective of the line. All operators on a production line can now react knowledgeably and specifically to changing circumstances.

Customized coaching

KHS’ various line coaching measures are as individual as its customers’ requirements. Each course is preceded by a comprehensive preliminary discussion, during which the actual state of the line is jointly analyzed. Armed with this knowledge, the KHS experts then make their way to the customer’s production shop where line coaching takes place.
 

Intensive and direct

There are plenty of instruction manuals, support hotlines and FAQs on offer, but just how practice-oriented are they? “With line coaching, we provide assistance precisely where it’s needed, namely directly on the line,” Schwarz states. So that intensive coaching has the longest possible effect, no more than two employees should take part per course. In consultation with the same, the information gleaned is then translated into specific exemplary measures for improvement.