Digitizing Processes Saves Thousands Per Hour

The Solution

Employees were losing their jobs because they weren’t doing the work effectively based on the Excel documentation. When they installed Dozuki, they could spend more time training through video. That helped them do the work at the proper rate.

Dozuki was privately piloted at one facility. Once results were seen, that facility became a lighthouse for rollout at other facilities.

The customer lacked documentation on key processes. With Dozuki, they were able to leverage our digital transformation services to rapidly create, digitize, and deploy standards in a format that all employees could easily understand.

How Has Dozuki Changed How You Access Process Documentation?

The manufacturer also lacked restrictions on who could access the documentation, which led to duplication, accidental deletion, and extra document handling. This was a lengthy process where updates to standards took weeks for approval, often getting physically lost in the process. Even upon completion, documents were rarely utilized on the floor. Workers generally were not comfortable navigating network drives, and spreadsheets were widely panned as confusing.

With Dozuki, Operators could access content directly from the floor with a QR code scan, even in the extreme environment of the forge. Ensuring the right content is in front of the operators at any given time was critical to reducing mistakes and quality issues.

The project champion remarked that moving forward with Dozuki was the easy choice, as Dozuki was starting to be recognized as the standard within the organization. When he transferred to a new facility, implementing Dozuki was one of his first initiatives. They skipped the pilot and went right into implementation.

How Has Dozuki Changed Your Day to Day Operations?

The customer’s old approval process (for moving process changes into production) involved too much back and forth between screens multiple times to review changes. This effort was very time consuming and confusing.

In Dozuki, operations stakeholders have a purpose-built document control system where they can see the full list of process documentation that needs approval, allowing them to quickly update content on the fly and instantly distribute it to operators on the frontline. It even includes a built-in audit trail to track all changes in case they need to be reverted.

“I was impressed with how the approval workflow provides a breakdown and a clear image of exactly what changed within a revision,” said the Supply Chain Engineer. He was blown away by the ease of use of Dozuki, improved visibility, and the increased accountability when a user reviews the change.