Digitalizing Occupational Safety for Manufacturing Facility

  • Service Product Development
  • Customer Major group of food companies
  • Year of implementation 2021 – ongoing

Case

Ensuring occupational safety is all about identifying and eliminating risks at workplaces in a timely manner. This applies to every situation that poses potential danger to employees and may interfere with normal manufacturing process at the enterprise.

All risks are monitored and eliminated in accordance with local laws. Previously, customer's plant used offline tools to work with manufacturing risks. The entire process was recorded in a special three-stage control log. It had all the information on what happened, when it happened, who is responsible for the particular area, who is responsible for eliminating the risk, who was the one that responded and eliminated the risk, what actions were taken in order to eliminate it and what happened as a result.

Customer

A large production corporate group with dozens of food manufacturing plants in EMEA. The corporation specializes in manufacture of confectionery, snacks and other food products. Daily production volume exceeds 1,200 tons of ready-to-ship products.

Business goals

  • #1 Data on labor protection processes was collected in different paper logs at individual enterprises. The central office did not have a full picture of what was happening, there was no transparency and no way to compare statistics.
  • #2 Information about incidents did not reach the holding company executives, it was possible for the local managers to block the flow of information.
  • #3 There was no way for employees to escalate the issue to a level above the factory management.
  • #4The process of identifying and eliminating occupational safety incidents was slow and did not comply with the standards.
  • #5 Employees had no motivation to identify incidents due to the complexity of information-providing process.

#1

Our approach

The customer decided to digitize the process of handling manufacturing risks and to seek the assistance of an established contractor which had proven to be reliable in other IT projects of the holding.

Before the development started, Loovatech team analyzed current problems and tasks set by the holding company's management, which the new IT product was expected to solve. Through the development of business requirements and thorough analysis, it was decided to develop a mobile application for employees and separate web console for engineering management. This product is available to all employees and is most effective in large-scale manufacturing.

After thorough analysis, product specifications were developed, then design and development teams were set to work. MVP went to production during the fifth month of the project. Pilot versions of mobile application were published on AppStore and Google Play.

#2

How does it work?

Pilot launch took place at one of the largest confectionery factories in EMEA. First results of occupational safety digitalization project were found effective by the management of corporate group. Plans for 2022 include scaling implemented IT solution to all customer plants.

Features of the pilot version

  • Initial risk evaluation and its detailed description, option to attach photos and videos to the incident record.
  • For each risk, a detailed history of changes is maintained.
  • Access rights system was implemented: each employee has access to relevant risks only.
  • The system has an administrative panel for advanced work with incidents, which occupational safety engineer has access to.
  • Mobile application makes it possible to quickly generate and download a ready-made three-stage control report.
  • Reports are standardized in accordance with local laws and can be sent to authorities without modification

#3

Result

  • With a smartphone, each employee can immediately report an incident and monitor its progress.
  • Employees can report incidents anonymously.
  • Corporate management can view all statistics on incidents of all factories in a uniform format, including their counts and resoultion speed, and make informed decisions based on that data.
  • Incident descriptions must be accompanied by photo and video evidence instead of previously used paper logs.
  • Ready-made reports for authorities can be downloaded in two clicks through the system interface.
  • The entire incident history is available in great detail, including comments and milestones.

Pilot launch took place at one of the largest confectionery factories in EMEA. First results of occupational safety digitalization project were found effective by the management of corporate group. Plans for 2022 include scaling implemented IT solution to all customer plants.

With a smartphone, each employee can immediately report an incident and monitor its progress. Employees can report incidents anonymously. Corporate management can view all statistics on incidents of all factories in a uniform format, including their counts and resoultion speed, and make informed decisions based on that data.

Incident descriptions must be accompanied by photo and video evidence instead of previously used paper logs. Ready-made reports for authorities can be downloaded in two clicks through the system interface. The entire incident history is available in great detail, including comments and milestones.

Technology stack

  • Backend TypeScript, Express.js, Node.js
  • Middleware nginx
  • Interface NativeScript
  • Storage and queues Redis
  • Hosting Deployment at the customer's facilities
  • DevOps TeamCity, Docker, Ansible
  • Tools JIRA, Confluence, Bitbucket, Sketch, Zeplin
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Expandable

Lorem Ipsum is simply dummy text of the printing and typesetting industry. Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book. It has survived not only five centuries, but also the leap into electronic typesetting, remaining essentially unchanged. It was popularised in the 1960s with the release of Letraset sheets containing Lorem Ipsum passages, and more recently with desktop publishing software like Aldus PageMaker including versions of Lorem Ipsum.

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1/3
Digital Transformation

Processes are time-consuming

Routine processes in production, sales, marketing or communicating between departments take a lot of time.
Digital Transformation

Human factor is an issue

Employees do the same actions in different ways, and there is a lot of human error.
Digital Transformation

There's duplication of work

Several systems and interfaces are needed to solve a single task, and switching between them takes time.
Digital Transformation

Productivity is low

There is lack of consistency and order; time-consuming information search and processing reduce the productivity of employees.

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Loovatech services

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