Workforce Key to Factory Efficiency: Page 3 of 3

Workforce Key to Factory Efficiency

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all of the acquisitions, “we had seven different time-keeping systems. To maintain all seven was costing us quite a bit in annual software maintenance costs,” he says, “and it was difficult to support seven systems.” So in 2005, Ball selected a Web-based workforce management system from Workbrain as a single solution for all of its plants. Following a pilot installation at a one plant in 2006, Ball now has seven plants using the system and plans to complete the rollout of the Infor Workbrain system to all of its North American plants by the first quarter of 2009, Karlzen says.

With the Infor Workbrain system, workers clock in and clock out for work shifts using proximity cards at time clocks on the plant floor. They can also use the system to record a change during the work day from one job to another that might have a different pay scale.

The improved accuracy afforded by the Infor Workbrain system is producing immediate savings, Karlzen says. “In our first plant, we saw a 46 percent reduction in on-demand checks,” he notes, in reference to mid-pay period checks issued to correct errors, such as underpayment for overtime hours. “In one of our other plants, we did not have a single on-demand check for the first three months,” Karlzen adds. “I think it’s because Workbrain is so customizable that we can configure any payroll that we have, so we don’t have the exceptions that we used to have.”

Indeed, the easy configurability of the system was a major selling point for Ball, says Karlzen, given that the company has both union and non-union plants in multiple states and locations, all with differing work rules. Ball plant officials in Canada and
Puerto Rico were also impressed with the system’s ability to convert almost instantaneously from English to French Canadian or Spanish, he adds.

The latter capability will be particularly important in a second phase of the project, when Ball plans to use the system’s self-service “employee transaction manager” module, enabling workers to view vacation and leave balances on the Web-based system, and to put in requests for time off. The self-service capability will translate to reduced administrative costs for Ball, he says.

Other savings will come through elimination of an estimated $100,000 per year in software maintenance costs, once the system is fully implemented across all Ball plants, says Karlzen, “because we won’t have to pay seven different vendors any more.”

Better decisions

He also expects that the centralized system will lead to better workforce decision making. “When we have seven different [time and attendance] systems, it’s almost impossible to get company-wide statistics on how many people are on FMLA (Family Medical and Leave Act) leave, how many are out sick, and what our lost time is,” Karlzen points out. “But by having a single system, we’ll be able to get enterprise-wide data on our labor and on what’s happening at our plants. And I think that’s going to be very valuable going forward.”

 

To see the accompanying sidebar to this story - "HCM Defined" - please visit www.automationworld.com/view-3424

For more information, search keyword “ workforce” at www.automationworld.com.

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