Digital Equipment Management in Just a Few Steps

Original: https://cli.im/article/detail/1909

In recent years, factory automation has been continuously advancing. I often hear about nearby factories implementing new information systems with great results. However, our factory has been using paper-based checkmarks for equipment inspections, making supervision difficult. Moreover, this data fails to create greater value and poses storage challenges. We wanted to improve equipment operation rates but lacked data support. I tried some systems, but the combination of software and hardware came with significant costs. Most importantly, from system selection to deployment, it took over half a year. Additionally, I heard that the headquarters was planning to implement a management system, so the project was put on hold.

At the beginning of the year, while visiting another factory, I noticed QR code tags on their equipment. I learned that they used CaoLiao to create a QR code equipment management system in just half a month, spending a little over two thousand yuan. This system enabled equipment file management and inspection records.

So, I decided to give it a try, as there was little cost involved. It took me about half a month to get familiar with CaoLiao and conduct a trial run in two workshops. Then, I spent another half a month tagging over 800 pieces of equipment across the entire factory with QR codes and officially put the system into use. Personally, I found the process quite fast.

Starting Digital Equipment Management Isn't Complicated

"Digitalization" may sound extensive and cumbersome, but in practice, it's not as difficult as it seems. It mainly involves organizing tasks, such as collecting and sorting current equipment information and various inspection paper forms. Since I have many other daily tasks, I assigned two interns to help organize the equipment information.

How to Quickly Collect Equipment Information

First, clarify what equipment information you need. This can be simple or complex, but the most important thing is to consider your actual needs. Let the information serve you, rather than collecting for the sake of collection. Start with the most basic information, such as workshop, equipment number, equipment name, specifications, model, responsible person, etc. Equipment drawings and operation manuals can be added based on actual conditions. Once you confirm your equipment information table, proceed with the formal organization work, dividing tasks by area.

Import Collected Information to Generate QR Codes

This step is relatively quick. Once you import the collected equipment information, you can generate all QR codes at once. If you are familiar with the process, it can be done in half a day. However, if you are using CaoLiao for the first time, you may need some time to learn the bulk QR codes generation function. This includes converting the currently used paper records into corresponding forms within the QR codes. From learning to actually creating the codes, it may take about three to four days.

How Frontline Employees Quickly Adapt After QR Codes Are Posted

In practice, this is hardly a concern. Everyone knows how to use WeChat, and after a brief 10-minute training, they were able to use the system. Initially, I only created QR code tags for two workshops, planning a one-month trial. After half a month, with no issues, we rolled it out comprehensively.

Frontline employees scan the QR codes with WeChat after inspections, directly check off inspection items, and take photos of the equipment's current operating condition. It's so simple that no one struggles. Previously, we used paper records, relying entirely on employee discipline. I often worried that they might just go through the motions, and there was no timely or effective way to verify. With QR codes, I can view all maintenance records and authentic photos on my phone, preventing falsification and enabling better supervision of inspections.

Clear Equipment Issues After Digitalization

Previously, without a data foundation, identifying frequently malfunctioning equipment required sifting through past inspection records or relying on subjective judgments, lacking intelligent methods. Now, with basic data in place, we use APIs to generate reports, allowing us to see at a glance how many equipment anomalies are being handled daily, what the issues are, and which equipment or faults recur frequently.

If you feel that digitalization is out of reach, start by addressing a specific problem, such as equipment files, fire extinguisher inspections, or access registrations. These are relatively easy to implement and help streamline processes. This approach allows you to achieve data standardization at the lowest cost, gradually accumulating data to reach a quantitative transformation.