June 23, 2016 Industry Forum Blog AR, Automechanika, Job Detail Sheets, S&B Automotive Academy, shortage of skilled workers, Skills learning, using Standard Procedures, virtual and augmented reality, VR, VR training Previously we’ve blogged about how virtual and augmented reality (VR and AR) is starting to be used for off-line training prior to full scale production, and also the benefits of using Standard Procedures in training. Both methods allow people to reach a higher level of skill more quickly. I’m sure you will agree, being able to collapse the learning curve is becoming increasingly important. Every sector is under pressure to reduce costs as well as facing a shortage of skilled workers. The use of VR raised some interesting questions, so we set off to find out if it realistically mimics work conditions. Along the way we also found out how some companies are making best use of Standard Procedures for training. The reality of VR and AR training At the recent Automechanika show we went to try our hands at VR training. Under the expert tuition of Jack, from S&B Automotive Academy, we sprayed our first car door. We asked Nathan, a Level 3 apprentice, how he found training using the VR equipment. “It’s easy” he replied instantly, of course he is of the gaming generation! He did stress though how this technology really paid off when it came time to try the real thing. The trainees get to learn and practise transferable techniques while building muscle memory on holding the gun at the correct angle and the speed of movement. The detailed on-screen feedback and opportunity to watch others practise, both add to the learning experience. Jack added, “The VR gun is a replica of a real spray gun, it vibrates when the trigger is pulled to simulate paint leaving the gun. The user sets the air pressure when they set the system up… [and] can pick the type of paint, colour, finish and body part.” The user can also change the fan setting controlling the spray width and thickness of the applied paint. S&B also do AR training in welding. The screen and sensors are incorporated into a real welding mask and links with a real welding head via QR codes at the tip. Jack promises that, “The welder is possibly the most realistic, just minus the heat”. And the benefits of VR training continue. Not only do trainees get to have more attempts at each skill, it costs much less. Their figures show the initial outlay, around £25,000, is paid back in little over a year. Significant and ongoing cost savings are made in materials, energy, preparation time and teaching time. Training in “the knack” Incorporated on best practise Job Detail Sheets is the “ease” point. This is the clever tip. It explains the hidden knack that experts on the job use. While many of us have used this key point option, a large Tier 1 automotive supplier has taken it a step further. They run specific training sessions for employees who write these documents. Using a piece of custom kit, they demonstrate how important using an ease point is to reduce training times and improve quality, cost and delivery performance. The ease point also helps reduces variation in time between employees conducting the same task. A blended approach? We think that either of these methods present excellent opportunities to improve our skills training outcomes. Or for the bold, why not try a combination of both? Thanks to S&B Academy, Bristol; especially Jack Andrews (Sales Consultant), Aaron Lang (Senior Lecturer) and Nathan Mardani (on the S&B Bespoke Apprenticeship Programme specialising in Paint).
June 15, 2016 Industry Forum Blog 5S, 7 Wastes, Autodata, Automechanika, cloud based solutions, connected car, foundation improvement techniques, garage, lean techniques in non-manufacturing, service and repair, Standardised Work, Visual Management Have you ever been frustrated when booking in your car in for a service or repair? Have you been put on hold, transferred multiple times or waited for a return call? Maybe you had to wait in a queue to check in? Worse still, your car wasn’t ready at the time it was promised? That’s just the customer facing side of the business. Technicians are faced with an ever increasing array of vehicles fitted with more and more complex technology. Stores and reception staff are also under pressure to accurately provide parts and information within ever decreasing deadlines. Where do we start? Although our garage is part of the service industry, the functions they perform can be described as a process. They may not be manufacturing but they are still using manpower, materials and machines (inputs) to make changes in line with customer requirements. We, the customer, judge their output in terms of quality, cost and delivery time. Once we understand this, we can capture each process and improve it. I use simple process flowcharts like this one. Many of the identified “problems” can be eliminated at very little cost by applying the foundation improvement techniques; 5S, 7 Wastes, Visual Management and Standardised Work. Once the simple, low cost solutions have been implemented, garages can look at how best to utilise the opportunities offered by cloud based technology. Simple, low cost solutions Take a look at the before (left) and after (right) shots of a repair workshop. While the before shot may look quite tidy, the improved layout and visual locations created using the 5S technique, resulted in a 50% saving in technician time searching for equipment. Improvements were also made in the time taken by each vehicle to go through the shop and a reduction in damage to parts removed during repair. Using the same techniques in the car parks and spares stores resulted in improved customer experience, time to retrieve parts form stores and part availability. Reception and customer enquiry experiences were also improved in time and accuracy by eliminating waste from the processes and creating standardised work procedures. So for the investment of some time, paint, hooks and labelling machines, you can improve competitiveness and profitability at the same time as enhancing customer satisfaction in terms of quality and delivery. Workshops of the future I recently attended the Automechanika show and saw many examples of how we can use cloud based technology to further eliminate wastes in our garage services. The example that stood out most was the vision presented by Autodata. Autodata currently provide up-to-date technical information for over 29,000 models using a cloud based system. Can you imagine even having the hard copy manuals for that, let alone retrieving the one for the job? Even if you did, they would appear in different formats and be quickly out of date. The beauty of their system is that other providers can develop applications to share the same platform. This will mean that the wastes incurred by accessing separate systems for bookings, queries, ordering parts and invoicing can also be eliminated. This system will also link with your connected car. Once your car has communicated its needs, the system will automatically arrange the details and order the parts. Then the booking slot, cost and directions will appear on your smartphone. All you have to do is press “YES”. I’m looking forward to this day, and who knows, perhaps my car will then drive itself in as well! For more help applying lean techniques in non-manufacturing situations contact the IF team.
