From data capture to daily action at Stone Bakery

Our Approach

We approached the work in three stages, starting with understanding what the team needed, making sure their Redzone setup was configured optimally, and finally deploying our manta reporting suite on top of it.

1. Understanding the opportunities

We started with a free day on site, meeting the team and running an assessment of their Redzone setup, using our Redzone Implementation Scorecard. It quickly became clear what the team were after, and where the biggest gaps were:

• Custom reporting views, in particular ones tying Redzone data together with their production plan
• Configuration issues, from product groupings through to downtime reason codes, that were limiting top down reporting and making the system harder to use day to day

We shared our findings the following day and proposed how we could work together to improve both data capture and reporting.

2. Reconfiguring their Redzone setup

With the findings agreed, we worked through the configuration itself, focusing on data quality and the front line operator experience:

• Set up new product groupings, cleaned up downtime reason codes, and updated area and line groupings
• Worked with the on-site engineering team to identify and resolve sensor issues that had been throwing off data accuracy
• Reset the daily operations review, the site's key operational meeting, to a standard SQPDC format built around the newly cleaned data

3. Deploying manta

With the data now reliable, we rolled out manta across the site, including two pieces of custom work built specifically for the team:

• Deployed manta on top of the cleaned Redzone data, complete with a custom product giveaway module and a bespoke connection to their production plan for measuring plan attainment
• Trained all key users across both shifts, in person
• Set up daily and weekly performance email subscriptions, so the team receives their key performance metrics without having to go looking for them

"manta has proven to be a very effective tool for reviewing and analysing Redzone performance data. Throughout the project, the Fighting Fish team were professional, easy to work with and delivered the agreed outputs within the committed timeline.

They invested time with all users across the business to ensure everyone had a clear understanding of both the system and how to use it effectively. Overall, the implementation was well managed, delivered on schedule, and has provided valuable insights into operational performance through enhanced Redzone reporting and analysis."

Aaron Whiteman, Operations Director

Results

The team now has performance data it can trust, and it's using it.

• A notable uplift in site performance and OEE, reflecting both the improvements the team made with their new visibility and the resolution of sensor faults that had been understating output
• Increased front line engagement with Redzone, with more comments posted and a marked rise in high fives and positive sentiment
• 100% satisfaction in the end of project feedback survey, with every respondent answering "Very satisfied"
• An ongoing relationship, with fully managed support, monthly status updates and continuous system improvements

"I have really enjoyed working with Aleksei and the manta team. Throughout our time working together, Aleksei has always been approachable, professional, and willing to listen to feedback and ideas. I have found manta to be a very useful tool that has helped improve visibility and understanding of performance across the business."

Jeffrey Sinclair, Shift Manager

Interested in a free assessment for your site?

Whether you're already using Redzone or still weighing up automated data capture, we'd be glad to come and spend a day on site, then share what we find and where we think the biggest opportunities are. For existing users of Redzone, that means a full review of your rollout against our Redzone Implementation Scorecard. If you're earlier in the journey, it's a conversation about what good would look like and what it would take to get there.

There's no obligation attached, and every site we visit gets our honest read based on the nuances of your operations. If you'd like to take us up on an assessment, or just want to hear more about how we work, please get in touch with the Fighting Fish team at hello@fightingfishltd.com.