Wiping Away Inefficiency: E-Records at Procter & Gamble

P&G brands are trusted in millions of living rooms, kitchens, laundry rooms, and bathrooms, passed down from generation to generation. Over the course of nearly two centuries, the company has challenged convention, led innovation, and helped shape culture, all while staying grounded in its purpose, values, and principles.

Since 1981, P&G's Dover, Delaware facility has been producing baby wipes around the clock, operating twenty-four hours a day, seven days a week, and shipping millions of packages sold across the US, Canada, and Puerto Rico. With production at that scale, ensuring release reliability and adherence to production schedules was paramount.

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As the team continuously improved its operation, paper records and excessive operator time spent manually entering data emerged as leading causes of inefficiency. Documentation issues, multiple touches on paperwork, and managing hard copies of documents were slowing releases and tying up inventory.

Realizing they needed a comprehensive MOM/MES solution to overcome these roadblocks, the P&G team turned to TrakSYS. To achieve the results they wanted, P&G worked with Parsec Automation, LLC certified partner Genesis Engineering to create a TrakSYS rollout focused heavily on electronic records and automatic and manual data entry within the platform.

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Utilizing TrakSYS's Task Management component, P&G recreated virtual quality release forms, with user-friendly dashboards enabling operators and QA teams to complete release forms directly in TrakSYS. The platform was configured to automatically track which purchase orders had all forms submitted and were cleared for release, putting the team on the path to making paper-based operations a thing of the past. TrakSYS web-based interfaces also let operators select the next Process Order for changeovers, automatically sending product information to the production floor, updating lot codes on date coders, and updating pallet label data, with changeover forms generated the same way.

The TrakSYS rollout reduced the time spent on data entry by the equivalent of 40 operator hours per week and eliminated products being held for up to two weeks due to multiple paperwork touches, reducing lead time and on-hand inventory. Delayed releases dropped by 80%, increasing on-time delivery.

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All operators, managers, and other designated parties can now view and manage pertinent documents from any device, anywhere, anytime, putting paper-based operations firmly in the past.