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Dentsply Sirona

Tulip’s apps helped Dentsply Sirona cut training times by 75% while reducing errors in a complex kitting process

Dentist office with medical devices

The Challenge

Dentsply Sirona is the world’s largest manufacturer of dental solutions. Their comprehensive catalogue of preventative, restorative, and cosmetic products are used in practices and labs world-wide, as are their best-in-class dental instruments.

Dentsply Sirona’s implants division processes thousands of custom orders each day. Since each order is custom to the patient, no two orders are alike. There are billions of potential kitting combinations, and executing every order on time demands skilled, attentive operators. In order to assure the quality of their shipments, Dentsply Sirona associates need to complete six months of training and shadowing before they were qualified to enter production. Further, process engineers lacked visibility into key areas of production, such as which components were shipped. This made it hard to maintain quality control and enable process improvement.

“Reducing the cognitive load of the operator makes it easier for them to focus on the work they have to do instead of figuring out what they should do.”

Senior Process Engineer

Dentsply Sirona

Guided workflows with pick-to-light capabilities for medical device assembly

The Results

Digital Apps Cut Training Times By 75% and Improved Reskilling

Turning paper-based work instructions into interactive digital apps allowed the senior process engineer to streamline new operator training. By following the apps, new operators were able to self-train and learn new skills much faster than before. Using Tulip for training facilitated cross-training with existing workers, letting them continuously gain new skills. With Tulip, these operators can be successfully re-assigned to areas of the operation where they are needed, when they are needed.

IoT Connected Kitting Apps Reduced Errors and Increased Traceability

A senior process engineer at Dentsply Sirona leveraged Tulip’s IoT capabilities to further improve the kitting app and error proof the process. The app controls Tulip’s Light Kit, a pick-to-light solution, so that the bin with the correct parts illuminates to guide the operator, ensuring he or she picks the right part for each kit. The app connects with a printer that prints a label with the order’s information, further preventing mistakes. Finally, the app integrates with a camera to take a photo of the package contents before shipping. This increased the traceability of orders and the accountability of workers involved.

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Day-in-the-life of a manufacturing facility illustration