VirGo eSOP offers Digitalization of SOPs. It offers improved efficiency, fewer errors, higher throughput, better visibility, better quality and higher operatorr efficiency! Simplified Documentation Companies have to maintain large no of documents for compliance. Records are essential for demonstrating that product meets designated quality standards. With VirGo digital SOPs you can document each step of a process. User data provides a record of the individual who executed the process, and a step-based application format provides a time marker for every step completion. All of the information can be store in excel sheets and is easily accessible when needed. These records can be exported to create a batch record report and, when combined with electronic logbooks, provide a record of process execution and validation. Standardization of Procedures Reduces Risk Paper-based instructions create the opportunity for variation. Even the best-written, clearest SOPs leave a window for individual interpretations. In highly regulated industries, these individual variations are a significant source of risk. Digital SOPs remove the chance of variation. These SOPs guarantee that workers are performing every step as specified. If errors do occur, in-app error reports let workers document the problem accurately, at the source. Controlled Permissions A common concern is that an end-user might accidentally change a critical setting. In a validated facility, such changes could have unintended, potentially severe consequences. VirGo digital SOPs tightly control which users have access to which feature. For example, the engineers creating SOPs on VirGo will have the ability to author and edit SOPs0. If necessary, the highest level of control can be reserved for IT, who are responsible for integrating and administering the platform. The admins can limit end-users power in the platform to running SOPs in production contexts. This ensures that digital systems are safe, compliant, and suited to local needs Better Quality with In Line Reporting Mistakes and non-conformances will inevitably happen. While it’s important to prevent them, it’s just as important that they’re documented correctly. VirGo Digital SOPs let operators report errors in line. Engineers can create custom error report forms for each process, enabling workers to provide the necessary information Data Integrity by Design Currently, documentation is a paper-based, manual process. Documenting processes by hand is inefficient, and doing so by hand increases the likelihood of error, illegible entries, or misfiling forms. VirGo SOP creation tool ensures that data meets the rigorous standards outlined in regulations. It is protected at workstations, in the cloud, or in your on-premise servers, as well as in transit.

1. 1
MAY 22
Virgo Innovation Pvt. Ltd.
Author: Udayan Modhe
VirGo “eSOP”
Case Studies
“Fastest way to ensure
consistency, reduced errors and
effective communication on shop-
floor is by embracing DIGITAL”

2. 2
Case Study: Increasing regulatory/ HSE compliance by digitalizing
SOPs
Challenges
Paper-based standard operating procedures (SOPs), for HSE, were cumbersome to use, enforce and update. As
a result, employees often resorted to memory or tribal knowledge, resulting in:
• Incorrect operational sequences resulted in potential safety issues
• Incomplete or inconsistent traceability of the processes, resulted in health and environmental issues
• Failure to meet ISO and regulatory compliance requirements
• Difficulty to maintain standards across manufacturing sites
The customer explored enterprise solutions and found they were time and cost prohibitive. It needed a different
way of thinking about both the problem and solution.
VirGo approach
To solve these issues, VirGo educated the shop-floor users about the benefits of digitalizing SOPs. In
coordination with those users, VirGo team digitally transformed the paper based production procedures into
guided work using the VirGO eSOP platform.
• Configured workflows to enforce role-based, step-by-step instructions that included time/ date stamp
• Confirmation of each completed step, supported by pictures, videos (when required)
• References in the form of PDF, picture or video for each step (whenever required)
• User-wise, shift-wise audit trail of each instance of all the eSOPs
Customer success
Presenting critical information to operators in the context of guided work is proving measurably successful.
The customer’s manufacturing ecosystem:
• Mitigated the regulatory compliance risk
• Reduced safety incidents to near-zero
• Improved traceability of all HSE related processes
 SOP instance data captured and stored on cloud for reference
• Platform is being scaled by the customer, across the manufacturing sites in India
A VEGA GROUP STEEL MANUFACTURING CUSTOMER WANTED TO
IMPROVE REGULATORY COMPLIANCES USING TECHNOLOGY

3. 3
Case Study : Productivity improvement by digitalizing SOPs
Situation
Reputed long product steel manufacturer with multiple plants across India had following situations:
• Frequent production loss and material rejection due to failure in monitor standard process parameters
• Paper based SOPs, some more than 100 pages, were required to be followed by operators for certain
production processes
The challenge
• Paper based SOPs were cumbersome for operators to use and often ignored
• Version control of SOPs across multiple sites was problematic
• Safety incidents, scrap and errors were trending upward as experienced employees retired
• A fairly manual process, made regulated tracking and tracing of each step in the steel manufacturing process
difficult and inconsistent
• Operators were required to login to multiple different systems to obtain needed information and record
transactions which distracted them from their work and impacted production output.
VirGo approach
VirGo eSOP platform was used to create and implement a digitized SOP solution. In four weeks it was
implemented in CCM department, followed by roll shop and guide box shop
• Site engineers configured intelligent workflows to enforce role-based and step-by-step instructions
• The solution included automated material verification (customized solution), that confirmed critical steps
were completed in the correct order.
• Supporting application SIMPLIWORKS (optional) alerted operators in real-time when actions were needed or
deviations occurred.
The value
• Reduced error incidents and improved efficiency through automated and guided work.
• Increased yield and line capacity.
• Improved operator effectiveness by consolidating the number of system interfaces and eliminating paper.
• Shortened the learning curve and ramp-up time for new hires.
A VEGA GROUP STEEL MANUFACTURING CUSTOMER WANTED TO
IMPROVE PRODUCTIVITY USING TECHNOLOGY
Safety and compliance • Workforce productivity • Quality and yield • Work orchestration