Goals:
- Error reduction
- Improved ergonomics
- Process digitization
Results:
- Zeroing out errors
- Training time reduced by about 80%
- Increased comfort and safety for workers
- 100% elimination of paper
Future Implementations:
- Extension of the solution to other areas of the plant
- Additional data collection and the devlopment of new KPIs
The Challenge
Zero imperfection goal: starting with picking
At the Whirlpool plant, the production cycle for hobs is distributed over 4 assembly lines, supplied by 2 supermarkets structured to accommodate up to 4,500 different components. Manufacturing handles the complexity resulting from the assembly of over 600 different products, with a paper-based picking process that produced errors, not-always reliable data, and the risk of losing or damaging the paper support.
The Solution
Spark, the the software platform that optimizes process logics in the intralogistics industry
The project team decided to intervene in one of the supermarkets by opting for the Pick-by-Light technology of electronic labels. The ESLs employ different LED colors to guide the work of multiple operators simultaneously and update their displays, indicating the quantities to be picked and the number of the current mission.
The integration of the solution with Whirlpool’s SAP MII management system is guaranteed by Spark, the KFI Software platform that enables the use of the most advanced field technologies according to optimized process logic. Client-side, the app displays the list of work orders in chronological order on the terminal, forcing the operator to follow a certain consequentiality, while the administrator views the operational process data in real time. This allows the progress of activities to be monitored through graphical dashboards.
The results
Zero errors and reduced training time thanks to the ESLs
During the first few weeks after implementation, no incorrect components reached the production line, and staff training time dropped by about 80%. In addition, data digitization has resulted in optimized management, improved operator ergonomics and a complete abandonment of paper, with positive effects on sustainability.
“Initially, the change brought some resistance. The more experienced workers were used to relying on their memory but now, thanks to the LEDs, they work better and they feel more confident.”
states Gaetano Porticone – WCM Engineer.
The upcoming steps include extending the system to the second supermarket as well. For Eleonora Notarpietro – Supply Chain Manager – in fact,
“the strength of such a solution is that it is extensible on a large scale to the whole warehouse, and this is the direction in which Whirlpool is moving. It is a project that we are very proud of, and we are always happy to present it to colleagues from other plants or visiting members of Management”.
Whirlpool facility in Melano – Fabriano (AN), Italia
The Whirlpool Corporation in 2015 built the European hub for the manufacturing of hobs for EMEA markets at its facility in Melano (AN). There, about 1.5 million household appliances flow across 12 production lines each year.
In 2021, in part thanks to the partnership with KFI, the plant obtained “Bronze Level” certification for its commitment to continuous improvement in terms of safety, quality, productivity and efficiency within the “Word Class Manufacturing” program.
Eleonora Notarpietro
Supply Chain Manager
Gaetano Perticone
WCM Engineer