"We are working more systematically on unplanned production stops today"

Fewer unplanned production stops are the goal for Husqvarna in Brastad, which has participated in the research project ReStart II. Photo: Markus Rytilahti.

“Through the research project, we have received useful tools and support that enable us to work more systematically to achieve our goal of reducing unplanned stops in production”, says Fredrik Vildefell, Head of Operations Support at Husqvarna in Brastad.

Unplanned production stops can be caused by a variety of factors, such as tool breakage, material defects, software updates, machine wear, or human errors. Restarting production after stops is often highly complex and can cause stress for both operators and maintenance staff.

It is not uncommon for 80% of maintenance work to be focused on urgent interruptions, while only 20% is allocated to preventive maintenance.

Different perspectives on work roles

At Husqvarna's factory in Brastad, crankshafts for forestry and garden machinery are manufactured. Production is largely automated and runs in a five-shift system. Like many other manufacturing companies, Husqvarna aims to reduce the number of production stoppages and therefore chose to participate in the ReStart II research project at University West over three years.

“As we began examining how we manage production stops and maintenance, it became clear that we needed to structure our problem analysis and review our working methods. We realized that we had different interpretations of our roles, and at times, even conflicting views on the root causes of production stops," says Fredrik.

Eight workshops

Representatives from all relevant departments participated in eight workshops together with researchers to identify problems and discuss possible solutions. The research method used is called Change Labs, which is based on activity theory and is commonly used in change management and organizational development. The method supports expansive learning within organizations, where researchers act as facilitators by asking questions while employees develop the solutions themselves.

“For us at Husqvarna, it has been both beneficial and valuable to receive support from an external party with academic expertise. The researchers have posed questions that have driven us forward. Some meetings have been challenging, but we have now developed an action plan. It covers everything from ensuring the quality of data from our production units to more clearly defining our various roles”, says Fredrik.

“Today, we have a greater understanding and awareness of each other’s expertise. We have established a new meeting structure for ongoing coordination and planning between departments. There is now better collaboration between shifts, and we work towards intermediate goals rather than just a few major objectives”, Fredrik concludes.

Testing AR glasses with an AI avatar

Operators at the Brastad factory have also tested whether AR glasses with an AI avatar could be helpful when resolving production stops.

“Receiving instructions via AR glasses could be an interesting solution for newly hired operators. So far, this is a prototype developed by our PhD student Nicole Tobisková”, says Monika Hattinger, project manager for ReStart II and researcher in Industrial Work-Integrated Learning.

“When unplanned production stops occurs, operators rely heavily on their own knowledge and ability to resolve the issue. It is crucial that operators collaborate with maintenance staff and others in critical situations. We need to take a holistic approach to disruptions in production and create sustainable work processes”, says Monika.

“This project highlights how incredibly complex the situation is when restarting production after unplanned stops. We have studied this field from an interdisciplinary approach and developed a conceptual framework for restarts, providing new knowledge and innovative solutions to address the complexity. We have taken a comprehensive approach, incorporating both practical and theoretical perspectives”, Monika adds.

Watch the video about ReStart II

FACTS

• The research project ReStart II involved the companies Husqvarna Brastad, Sansera Sweden, GKN Aerospace, and MaintMaster Systems.
• The project consisted of two work packages:
  - Researchers studied the companies’ working methods, IT system usage, routines, and instructions. They also engaged with personnel using the Change Labs research method.
  - Researchers developed and tested various prototypes for operator support, including AR glasses and an AI avatar to facilitate troubleshooting during production restarts.
• Students at the bachelor’s and master’s levels conducted seven thesis projects in collaboration with the companies.
• The project was funded by the Knowledge Foundation (KK-stiftelsen).

Contact person: Monika Hattinger, University West