Case Study 3: Sarah, Plant Manager (The People Problem)

Setup

Sarah, a Plant Manager, loved her people. But lately, the stress was visible. Quality issues were mounting, downtime was creeping up, and the atmosphere on the shop floor was tense.

Challenge

“It’s not that my team doesn’t care,” she said. “They’ve just stopped believing the system works for them.” Operators felt ignored, supervisors felt overwhelmed, and small issues snowballed into costly downtime.

Struggle

Sarah bore the brunt of the frustration. Every day felt like she was caught between leadership’s demands and her team’s burnout. She knew the real problem wasn’t effort—it was communication.

Intervention

We introduced TSRB’s Digital Andon system, integrated into our Production Intelligence platform. Operators gained the ability to flag issues instantly, supervisors received real-time alerts, and problems were addressed before they spiraled.

Resolution

Within weeks, downtime dropped by 18%. But the real win wasn’t just efficiency—it was trust. For the first time in years, operators felt heard, supervisors felt supported, and Sarah’s plant ran with a renewed sense of unity. The system didn’t just fix machines—it restored confidence.