Efficient Plant Jan./Feb. 2021 - 27

feature | solution focus
 identifying and repairing
any equipment problems
 using collected data to
drive continuous cycles of
improvement.

are followed, and help manage
and collect daily checks on
the machines.
The 22-month improvement metrics from Purple's
L2L Maintenance rollout
show:
 52% reduction in equipment
failures
 54% reduction in equipment
downtime
 1,400% increase in completed preventive-maintenance events
 42% increase in on-time completion of
preventive-maintenance events.

ACCELERATING
PRODUCTION
Most of the company's production equipment was proprietary
technology that didn't exist in
the manufacturing industry. This
required more information collection to
continuously validate and improve performance for each machine. It was important
that a software tool was chosen that would
expand in purpose and scope as it was
adapted to manage formal processes and
procedures for collecting data.
L2L's success at improving Purple's
performance in the maintenance department led to deploying the company's LES
Production Module. Production processes
demanded clarity of systemic issues. A
lack of performance on the plant floor was
slowing down production of the company's
most-popular products. Real-time data was
needed to take action and improve performance.
The L2L Production Module was used
to track and display real-time production
metrics. This brought increased visibility
to abnormalities and showed opportunities
for waste reduction throughout the entire
production process. More important, it
improved the system of measuring hourly
equipment and manufacturing status in real
time. L2L's LES was used to absorb Purple's
older safety and quality systems, which the
software accomplished with ease.

A SOFT LANDING
Two years after adopting L2L, Purple has
seen production improvement across the
board. LES is currently used by the maintenance staff of 16 mechanics, two MRO

JAN/FEB 2021

EP2101fsolfocus.indd 27

Purple provides unique products to the sleep
industry and implemented several L2L software
solutions in its Utah manufacturing facility.

clerks, and a maintenance planner. Purples'
safety, quality, and production teams all use
the system to capture events on the factory
floor as part of the hourly production
cadence. According to Andrew Clarke, VP
Engineering & Manufacturing, " The system
has given our employees the tools to see the
highest impact opportunities for improvement and a way to visually see the impact of
actions taken to address them. "
Operators on each production line,
using the L2L Production Module, see
their schedule displayed on a monitor. The
monitor shows the success of the line in
real time, providing complete transparency.
Each member of the 400-person production
team at the Utah plant logs in to the line
they're working on to properly track key
performance indicators. This has provided
data that was previously unavailable, yet
vitally important. The Production Module
has led to double-digit improvements in
target KPIs.
The production lines use hourly and daily
checklists to maintain a high level of quality,
ensure that standard operating procedures

NEW REALITY
L2L has driven change in Purple's bottom-line business performance and cultural
development. The software has taken the
company from spreadsheet data collection to digital real time. The company also
needed a solution for communicating between four shifts. The LES is standardizing
procedures and training between shifts and
making the platform the system of record
on the manufacturing floor.
Employees can find the goals that have
been set and track where along the continuum they stand in relation to their completion. These positive developments allow
the company to improve manufacturing
performance, ensuring products are made
in the most cost-effective manner.
Production has increased because assets
are running better, longer. Communication
across the company has improved, and
there's now a platform that helps pinpoint
key problems and allows the company to fix
them immediately.
The greatest sign of success is that it's
now become common to end a company
developmental conversation with, " Let's do
that in L2L too! " EP
Go to L2L.com for more information.
EFFICIENTPLANTMAG.COM |

27

1/26/21 12:12 PM


http://www.L2L.com http://www.EFFICIENTPLANTMAG.COM

Efficient Plant Jan./Feb. 2021

Table of Contents for the Digital Edition of Efficient Plant Jan./Feb. 2021

Efficient Plant Jan./Feb. 2021 - Cover1
Efficient Plant Jan./Feb. 2021 - Cover2
Efficient Plant Jan./Feb. 2021 - 1
Efficient Plant Jan./Feb. 2021 - 2
Efficient Plant Jan./Feb. 2021 - 3
Efficient Plant Jan./Feb. 2021 - 4
Efficient Plant Jan./Feb. 2021 - 5
Efficient Plant Jan./Feb. 2021 - 6
Efficient Plant Jan./Feb. 2021 - 7
Efficient Plant Jan./Feb. 2021 - 8
Efficient Plant Jan./Feb. 2021 - 9
Efficient Plant Jan./Feb. 2021 - 10
Efficient Plant Jan./Feb. 2021 - 11
Efficient Plant Jan./Feb. 2021 - 12
Efficient Plant Jan./Feb. 2021 - 13
Efficient Plant Jan./Feb. 2021 - 14
Efficient Plant Jan./Feb. 2021 - 15
Efficient Plant Jan./Feb. 2021 - 16
Efficient Plant Jan./Feb. 2021 - 17
Efficient Plant Jan./Feb. 2021 - 18
Efficient Plant Jan./Feb. 2021 - 19
Efficient Plant Jan./Feb. 2021 - 20
Efficient Plant Jan./Feb. 2021 - 21
Efficient Plant Jan./Feb. 2021 - 22
Efficient Plant Jan./Feb. 2021 - 23
Efficient Plant Jan./Feb. 2021 - 24
Efficient Plant Jan./Feb. 2021 - 25
Efficient Plant Jan./Feb. 2021 - 26
Efficient Plant Jan./Feb. 2021 - 27
Efficient Plant Jan./Feb. 2021 - 28
Efficient Plant Jan./Feb. 2021 - 29
Efficient Plant Jan./Feb. 2021 - 30
Efficient Plant Jan./Feb. 2021 - 31
Efficient Plant Jan./Feb. 2021 - 32
Efficient Plant Jan./Feb. 2021 - Cover3
Efficient Plant Jan./Feb. 2021 - Cover4
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-april-2022
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-october-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-june-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanfeb2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com