Canvas Envision: Perspective and Confessions of a Recovering Plant Manager
/Next Generation Training and Work Instructions Platform
Extending the digital thread to the frontlines of manufactures with best-in-class, model-based work instructions
By Lloyd Rogers
Summary
Canvas Envision provides a digital work instructions platform that is truly next generation. How I wish I had something like this 15 years ago!
I’m writing this blog as a former plant manager for an automotive supplier. I spent 30 years in the auto industry with my last 5 years running a manufacturing facility in Mexico. As I’m sure you are all aware, product quality is NOT an option in the auto industry. It is a must. Suppliers are on the hook for years after their products are shipped to the OEM.
The plant I ran required that we maintain the equipment used to produce the parts, as well as, conduct inspections at various stages of the manufacturing process. At the time, we used written documents distributed across the plants. We provided versions in both English and Spanish.
We had over 150 unique pieces of machinery and jigs to maintain. Additionally, we had about 25 inspection and sampling stations. So collectively there were over a thousand instructional documents - in three languages – active in parallel. This results in about 3,000 different documents! In spite of good intentions, the process to create and maintain these was extraordinarily time consuming and prone to errors.
After discovering Canvas Envision, it triggered the “oh how I wished I had something like this” thought. I wanted to share these thoughts on how this platform would have dramatically improved efficiencies, accuracy, and even my team’s morale.
Creating the Work Instructions
Creating the needed work instructions was a laborious and time-consuming effort. Activities highlights included …
researching and hunting down accurate product descriptions and drawings for the production equipment and jigs
creating 2D visual “snap shots” from the drawings
writing up the instructions in English and then translating into Spanish
If we had Canvas Envision back then, the process would have been dramatically different. It would have included …
leveraging the released 3D CAD models (regardless of format) directly from within the product data management (PDM) or product lifecycle management (PLM) solution
incorporating these models in the work instructions - allowing users to interact with the model, by rotating, exploding assemblies, isolating parts, etc.
animating processes using the 3D CAD model
providing “data capturing” options to collect inspection results, observations, etc.
leveraging AI to assist with generating the instructions in English
automatically translating into Spanish
Moreover, if the CAD model changes within the PLM solution, users are alerted so they can go back and make updates as needed.
The significant benefits of this revised approach would be …
optimized reused
accurate content based on release product data
accelerated creation of content for both language requirements
Content Consumption
So let me switch over to the consumption side of the process. 15 years ago, it was all about the paper. The recurring challenge was keeping the documents up to date … and then making sure the old versions were pulled off the floor when an update came out. As you can imagine - with over 360 different documents needed at any one time - this was nearly impossible, resulting in myriad problems.
With Canvas Envision we would have had the following …
only the current version would be available
this digital version would be available on mobile devices (like iPads) and could even be used without internet access (just like paper 😊)
users would be provided “guided” instructions which would eliminate jumping ahead and/or missing a step
the instructions would provide the ability to interact with the 3D model - such as rotate, zoom, explode, and isolate needed information
user could capture results of an inspection and associate this with the specific steps in the instructions
a supervisor could be “called” as needed
users would be able to initiate a problem report or investigation request. This would automatically be sent back to the PLM environment, thereby leveraging the existing workflow processes
and all of this could be done in the language of choice
Moreover, it could be argued that the “enjoyment” factor of the workers would be much greater.
What does this all Mean
We hear a lot about the connected worker movement in manufacturing. Critical to the success of this wider initiative is the need to ensure the flow of knowledge between the shop floor and “top floor”, and even between different organizations within the same ecosystem.
Canvas Envision offers a compelling value proposition …
slash production errors by up to 90% by providing frontline workers with accurate, interactive, and 3D-based work instructions. Since Envision dramatically reduces the risk of assembly errors, this could lead to substantial savings in rework costs and scrap reduction
boost worker productivity by 40% with clear, visual instructions. This would have enabled workers to complete their tasks more quickly and accurately
cut training time in half. Envision's interactive, multimedia-rich instructions make it easier for new employees to learn processes quickly, reducing onboarding costs and improving workforce flexibility
drive continuous improvement with Envision's capabilities to drive feedback directly to the “system of record.” This allows for the existing change processes of the PLM platform to be utilized.
Ultimately, this is all about reducing the cost of quality (CoQ). When I think about the CoQ incurred during my time as a plant manager, the ROI of a Canvas Envision investment would have easily been achieved in less than a month! Unfortunately for me, this technology was not available during my days as a Plant Manager. I envy those that are able to make use of it today to provide value to their organizations!
