World Class Training with Digital Work Instructions: A Case Study on a Fortune 500 Food and Beverage Company
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Education
- Retail
Applicable Functions
- Facility Management
- Maintenance
Use Cases
- Personnel Tracking & Monitoring
- Virtual Training
Services
- Training
About The Customer
The customer in this case study is a Fortune 500 manufacturer of branded consumer foods and pet food products sold through retail stores. Over the past 150 years, they have built a portfolio of more than 100 brands worldwide. Their goal is to manufacture human and pet food products that provide great taste, nutrition, convenience, and value for consumers. To achieve this, they recognized the need for a frontline digital transformation to create a world-class training and upskilling program. They have already deployed Dozuki, a digital work instruction platform, at five of their facilities, with plans for more.
The Challenge
The company was grappling with several challenges, including increasing staff retirements, lack of digitized processes, and absence of a formal training program. These issues were leading to spikes in quality problems and downtime. As new frontline employees joined, there was no program in place to upskill them properly to meet production demands, leading to a repetitive cycle of issues. The company was losing approximately $3 million per year due to poor frontline training. Their facilities historically relied on job shadowing and word of mouth for operator training, which was proving to be inadequate. With high numbers of retiring staff and outdated documentation held in paper binders, standardizing process information was a pressing need. Changeover errors in their sensitive assembly lines for perishable products were costing the company millions of dollars a year in defects, supply chain issues, and profit losses.
The Solution
The company chose Dozuki as a central solution for maintaining changeover processes. Dozuki provided their frontline employees with easy and instant access to key information from a tablet, replacing the previous system where knowledge was concentrated with a single person per shift. Initially, Dozuki was piloted at one facility and after showing positive results, it was rolled out across the enterprise. With Dozuki, work instructions now had photos and videos embedded in them, providing a visual aid to reinforce processes and reduce errors. All frontline operators were granted permission to be authors, enabling them to create a process if they didn’t see something on their site. The company also started deploying training courses to their maintenance technicians, some of whom have been in their roles for over 16 years. This digital training helped close gaps in basic manufacturing frontline knowledge, reducing potential downtime.
Operational Impact
Quantitative Benefit
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