QR Codes Boost Efficiency at Milwaukee Tool

Reducing Downtime With QR Code Training | Milwaukee Tool + Tooling U-SME 

At SME's recent RAPID + TCT event in Detroit, within the innovative Mission Critical: Workforce 2030 experience, there was a fascinating discussion on a groundbreaking solution to a common manufacturing challenge: machine downtime. John Hindman, Director of Talent and Workforce Services at Tooling U-SME, sat down with Dan Sellhausen, Manager of the Rapid Innovation Center at Milwaukee Tool, for an “SME Insights” discussion to explore how a seemingly simple technology – QR codes – is making a significant impact on efficiency, productivity, and employee development. 

Sellhausen, at the helm of Milwaukee Tool's Rapid Innovation Center, provided a deep dive into the Center's critical role and the unique hurdles it faces. Established in the mid-2000s, the Rapid Innovation Center serves as a prototyping lab, dedicated to delivering "new-to-the-world products with same-day results." As Sellhausen explained, their primary focus is on supporting the power tool accessory business unit, handling all in-house prototyping at their corporate headquarters. This rapid prototyping model is designed to "streamline our prototyping process, get those prototypes on test and in the engineer's hands with the most efficiency possible."  

The Challenge of Downtime 

However, this commitment to speed and innovation introduces specific workforce challenges. Sellhausen highlighted the "dynamic workplace environment" within the prototyping lab. While this agility is crucial, it also means that equipment usage can fluctuate dramatically. "We could be running certain pieces of equipment for a period of time to support a certain project need, and it could be weeks, it could be months, and then, you know, like a flip of a switch, now we're supporting another project need."  

This constant pivoting can lead to machines sitting idle for extended periods, sometimes eight months or even longer. According to Sellhausen, the challenge was to 'bridge that gap' and streamline the transition—from a setup where an operator runs one machine at a time, pauses for long stretches, and then has to restart operations. “How do we increase our uptime and our efficiencies in that?" 

The Simplicity of QR Codes 

This is where the innovative QR code project comes into play. Hindman introduced the concept, noting that for many, QR codes can be intimidating. "It’s new technology and they run away from it," he said. Yet, Milwaukee Tool, in collaboration with Tooling U-SME, embraced the technology as a solution to reduce inefficiencies and potential downtime stemming from infrequent machine use. 

Sellhausen elaborated on the simplicity and power of their QR code system. By affixing a QR code directly to their prototyping equipment, they created a centralized hub for all essential machine information. Through the QR code, operators have access to training materials, preventative maintenance plans, machine manuals, and even troubleshooting documentation and procedures. What makes this particularly impactful for Milwaukee Tool's unique prototyping process is the ability to capture specific, even subtle, variations in setups and programming.  

As Sellhausen noted, a part that appears identical one week might be "in essence completely different" the next. The QR code system allows them to document unique setups, programming notes, job aids, and even visual or video aids. This is invaluable when, for example, a second-shift operator needs to replicate a task performed by a first-shift programmer. " Now, our second-shift and off-shift operators no longer have to wait for first-shift staff or subject matter experts to return the next day to complete work on that equipment. That really increases our uptime and our efficiencies," he said. 

Critical, On-Demand Information 

Beyond the convenience aspect, the system significantly reduces time wasted searching for information. Sellhausen painted a vivid picture of the previous challenges, such as "paging through the machine manual or looking through a shared file drive, maybe even handwritten notes in somebody's toolbox." Furthermore, the QR code system provides critical support for crash recoveries. While no one wants to discuss machine crashes, they are an inevitable reality, admitted Sellhausen. Having immediate access to recovery procedures means off-shift personnel don't need to reach out to a manufacturer after hours and then wait for the next business day to hear back—or wait to speak with a machine operator from another shift who has encountered the problem previously. Instead, the documentation is at their fingertips.  

Thoughtful Implementation 

The implementation process itself was a testament to thoughtful planning and collaboration. Sellhausen highlighted the crucial role of Milwaukee Tool’s partnership with Tooling U-SME and the collaboration that took place in the planning, development, and execution phases of the project.  

The initial phase involved a team from Tooling U-SME coming on site to work with Milwaukee Tool staff and gather documentation and video footage. “When we partnered with SME, we had a group of individuals come in. They're working with our subject matter experts on the machine, they're referencing the machine manufacturer, they're capturing all the video aids—and this isn't just a GoPro on somebody, following them around over their shoulder, flipping switches, and going through menus. This is a very professional documentation of a machine startup, or a crash recovery, or maybe it's a certain program, or machine homing, whatever it might be. They're able to provide that video visual aid for us.” 

After Tooling U-SME staff captured the information and turned it into actionable materials, Milwaukee Tool prepared its SharePoint site to store the content and began generating QR codes for easy access. To improve readability and longevity in the dusty, coolant-prone lab, they laser-etched the codes onto anodized steel and attached them to each machine. Then, with IT’s assistance arranging permissions, operators were able to begin accessing the content by scanning codes with a mobile device. “It takes them right to the SharePoint site in the file folder, where all these visual aids, job aids—everything is housed right there,” said Sellhausen.  

Overcoming Resistance Through Teamwork 

Perhaps one of the most critical aspects of any new technology implementation is the human element: change management. Hindman inquired about the workforce's reaction to this new initiative. Sellhausen acknowledged that "change is never easy," but Milwaukee Tool proactively addressed potential pushback by involving their machinists from the outset. "How we overcame that and how we rolled this out was by partnering with our machinists. ‘You guys are the experts on this. You tell us what you would like to see. Tell us how you go through this on a daily basis. How are you going to use this?’ " By soliciting feedback and empowering operators to contribute to the system's development, they achieved crucial buy-in. This collaborative approach ensured that the solution was truly useful and adopted by those who would be accessing it daily, rather than being perceived as a top-down mandate. 

Looking ahead, Sellhausen confirmed that this QR code initiative is "just a stepping stone" for Milwaukee Tool. The potential for expansion is vast. Beyond machine documentation, the system can be leveraged for tasks like tracking preventative maintenance schedules, coolant changes, or tooling updates. Sellhausen highlighted the broad applicability of the system to maintain optimal operational readiness across all their prototyping equipment. 

 "If we're going to a piece of equipment we haven't used in a year, how do we know that the preventative maintenance plan is up to date?"  

A Model of Collaboration  

This collaboration between Tooling U-SME and Milwaukee Tool demonstrates a powerful model for addressing workforce challenges and leveraging technology to enhance efficiency. By understanding the unique needs of their operations and actively involving their workforce, Milwaukee Tool has successfully implemented a solution that significantly reduces downtime and empowers their employees. 

To learn more about this innovative project and how SME can help your organization streamline operations and empower your workforce, watch the interview, or contact info@toolingu.com.