Rational behind OPEX (Operational Excellence) App
When analysing troubles previously experienced scaling operations I concluded we lacked a standardised feedback loop framework for improvement across the organisation.
The tools we did have were fragmented, resulting in App Fatigue. moving from one app to another, each with a separate login and different user interfaces increasing the friction to adoption and use. Examples:
Safety
→
TIA: Users felt the drop box was over-complex, or there were login problems, so TIAs weren’t submitted; people gave up and risks were left exposed.
Quality
→
Appeared to be managed via fragmented Excel files with differing standards across departments.
5S
→
The app constantly changed, but focused more on reporting deviations rather than solving how to prevent a repeat.
Gemba
→
Nothing—so it didn’t get done.
CI
→
No organizational standard; every department did it differently. Standards remained at departmental level as improvements were rarely shared externally.
Maintenance
→
Used Dynamics as a closed system so without transparency so without oversight there was little continuous improvement
Work Instructions
→
Used MS Word, so not great to read on a phone. Images were too small and coulnd't be zoomed. Required knowledge to find them, instead of instictive contextual links at the point of use.
Machine/Quality Checks
→
Inefficient to complete, inpenetrable distributed excel file records, easily lost and lacking integrity.
When analysing these subjects, one phrase repeated in my mind:
"Everything is a feedback loop."
While they maybe different subjects... how we resolve them can follow a lean, single standardised process.
- Safety, Quality, 5S, Gemba, and CI
- Internal orders and requests (e.g., new PPE or support requests)
- Maintenance requests logically linked to an Assets, Risk Assessments, PFMEA and Continuous Improvement tools
- Work Instructions created using the same standard tools contextually linked and integrated
- Checklists - Are they being done and deviations investigated, corrected and preventing repeat
- Data - Stored and backed up in a robust enterprise scalable structure, sharable if needed with other apps (example ERP)
- Data with Integrity - Soft deletes and all changes recording who, when, what was changed from:->to: complies with ISO 9001/45001
"Why learn 5+ different apps, when all subjects can be handled in a single standard user experience?
Using a single user interface simplifies training and adoption and requires a robust single data source/storage/retrieval/backup."
Other Features:
- Risk Assessments → Heatmapped to visualize live risk to people and operations
- PFMEA → Heat Mapped to visualize risk exposure for every Asset and Process Step. Collapsable and well presented to make completion a pleasure rather than using an overcrowded excel file.
- Defect Catalogue → Integrated into PFMEA to provide contextual data for analysis and escalation, example, from a trend of failures, generate an 8D to close the loop from discovery to resolution and new standard disemination
Pipeline Features:
- Scheduler for Walks: Defines when a user is expected to complete pre-defined walks, audits and meetings.
- Once Maintenace Request data is stored, AI can be used to dynamically provide real time solutions based on previous events.
- Make it prettier when viewed on phones
- Improved User management tools
- Improved User selection features to allocate feedback item tasks to users
- Define clearer permissions for access controls to specific data.
- Integrate Metrics to better define standards and quantify improvement.
- Integrate KPIs to visualize progress, compliance and highlight stale initiatives.
- Multi-Language support.