Visual Training Aids Support a Critical Client Audit
Q. When a newly relocated line fails a client audit and you have limited time to address the nonconformances, how do you quickly achieve corrective and preventive actions?
Client
A plant in Philadelphia, with headquarters in Germany, bringing up a new line and making caramel sauce for the first time.
Challenges
A production line dedicated to an important client was being moved to a different facility. Once the line was relocated and operational, a client audit discovered numerous nonconformances, including some related to material- and product-handling across the entire line. A final audit was scheduled a month later. If the manufacturer did not address the audit issues by then, it risked losing its client.
Solutions
The manufacturer requested our help to quickly improve operator performance in some areas identified by the audit. Working on site with operations and quality personnel, we analyzed, captured, and validated technical information. Then, using this knowledge and working with key operators, we identified the desired performance—the standard work—and organized it in one point lessons (OPLs) and other training support materials.
These documents targeted the required corrective actions for safely handling product and materials. The training support materials defined standard work and clarified key principles, roles, and tasks in an easy to use, visual format. The one point lessons employed simple visuals to further summarize key points. These job aids were posted at key locations on the line.
Results
The operators improved how they handled materials and product to specifications. The plant passed its audit, saved its relationship with the critical client, and started production.
