AI INCIDENT & WELL-BEING CENTER
AI provides first response
for nighttime trouble
on 24-hour production lines.
Nighttime callouts reduced from 270 to 52 per year
NIGHT CALL REDUCTION
Annual nighttime callouts were significantly reduced, improving the quality of life of maintenance staff.
Industry
Paper manufacturing and processing
Implementation scope
Production lines and maintenance department
Implementation period
5-week PoC → 5-month phased rollout
BACKGROUND
An AI system that realizes “night shifts without callouts”
The paper industry typically operates 24 hours a day, and when trouble occurs at night, the only option is often to call veteran maintenance staff from home.
Company J had 270 nighttime callouts per year, and fatigue and turnover among maintenance staff had become a management issue.
As competition for talent intensified across the industry, achieving “night shifts without callouts” was positioned by management as a priority because it was critical to employee retention.
By introducing CLAVI Mining, the company built a system in which AI handles first-response support during night shifts, protecting both people and the organization.
BEFORE
Challenges before implementation
INCIDENT 01
Nighttime trouble continued to be a situation where staff felt they “had to call someone to resolve it,” frequently interrupting the sleep of veteran maintenance personnel and increasing their intention to leave. In fact, two skilled maintenance employees had left over the past three years, making “night shifts without callouts” a top management priority.
INCIDENT 02
Night-shift members were forced to decide whether to call someone or handle the issue themselves and take the risk, while accountability in the event of a serious incident remained unclear. Interviews with site managers also showed that many felt the psychological burden of night shifts was more than three times that of day shifts.
INCIDENT 03
Past troubleshooting records were written in paper maintenance logs and stored away without being used. There were multiple cases where the same symptom had occurred three years earlier, but no one knew how it had been handled at the time.
WHY CLAVI
Reasons for choosing CLAVI
TRUST POINT 01
At Company J’s site, a key requirement was that AI could support the decision of whether or not to call someone. CLAVI Mining was highly rated because it could instantly present similar past cases and provide response procedures and risk assessments with supporting evidence.
TRUST POINT 02
Hallucination suppression through patented technology was essential for trusting AI during night shifts, when fewer people are available to verify information. During PoC interviews with all maintenance managers, 94% responded that they would feel comfortable using it during night shifts.
TRUST POINT 03
The ability of AI to read handwritten maintenance-log images was also decisive. The fact that ten years of past cases could be used immediately without reorganizing them helped drive decision-making on site.
AFTER
Effects after implementation
IMPACT 01
81% decrease
Nighttime callouts
[Nighttime callouts] 270 per year → 52 per year, an 81% reduction. The quality of life of veteran maintenance staff improved significantly.
IMPACT 02
63% shorter
Nighttime troubleshooting time
[Nighttime troubleshooting time] Average 60 minutes → average 22 minutes, a 63% reduction. The reduction in production downtime was also substantial.
IMPACT 03
+28 hrs/month
Sleep time
[Sleep time for maintenance staff] Increased by an average of 28 hours per month due to fewer callouts. Improvements in health-check indicators have also been observed.
IMPACT 04
58% lower
Turnover rate
[Turnover rate] Turnover in the maintenance department decreased by 58% year over year. “Night shifts without callouts” became an incentive for retention. In the hiring market, the company’s reputation improved as a workplace where night shifts are not dependent on veteran staff.
INSIGHTS / NEXT
Insights from this case and future development
STRATEGY FLOW
AI utilization is a management measure that protects people.
STRATEGY 01
The essence of Company J’s case is the recognition that AI utilization is a management measure that protects people. Achieving “night shifts without callouts” is directly connected to both talent retention and health management for 24-hour manufacturing operations, and it sits at the intersection of business strategy, HR strategy, and on-site improvement.
STRATEGY 02
After implementing it on 24-hour production lines, Company J positioned “night shifts without callouts” as an important element of its BCP (business continuity plan). CLAVI Mining is being used as a core technology for building a system in which sites can respond independently during disasters and pandemics.
STRATEGY 03
Based on the successful experience in the maintenance department, the company is also expanding the approach to quality control, equipment engineering, and environmental management. The management policy of “keeping operations running while protecting people” is being realized through AI utilization. AI has become an important option as a management method that balances employee well-being with business continuity.
EXECUTIVE COMMENT
Comment from the Head of Maintenance: “AI that protects people. That is our honest impression after implementation. We have even heard from employees’ families that they feel relieved because staff are no longer called out in the middle of the night, and the impact on talent retention has exceeded expectations.”
WORKFORCE EFFECT
Night shifts without callouts
Applications for night shifts also improved, making it easier to secure night-shift personnel, which had previously been difficult. “Night shifts without callouts” has begun to function as a brand, and inquiries from talent at other companies in the industry are increasing. This is a case where AI implementation became positioned as a core labor-strategy initiative.