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ImprovingProductivity and OEE Utilizing RealTime Manufacturing Intelligence Solutions

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'A Standard Metric for Production Loss' ... Allows a single dashboard to host controls sourcing Metrics data from multiple servers ... – PowerPoint PPT presentation

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Title: ImprovingProductivity and OEE Utilizing RealTime Manufacturing Intelligence Solutions


1
Improving Productivity and OEE Utilizing
Real-Time Manufacturing Intelligence Solutions
  • How is your plant performing?

John Cavalenes Director of MES Solutions Citect
Americas
2
Recent industry trends
  • Lean Manufacturing and other improvement
    initiatives have been embraced by manufacturers
  • Cutting fixed costs is reaching a point of
    diminishing returns
  • Automation systems generate plenty of data, but
    plant personnel need information to make the
    operation decisions that improve the business
    performance
  • The bulk of automation budgets is spent on
    process control and not on decision-support and
    work process optimization
  • Managers are concerned with increasing
    productivity of plants

3
How do managers measure productivity?
  • The use of clipboards and data entry by plant
    personnel
  • Data is combined by office personnel to determine
    line and plant utilization, yield, and other
    measures, such as OEE
  • Business executives receive data usually days
    after production has occurred precluding them
    from making timely decisions which will
    dramatically improve plant operations
  • What plants need is timely information to use
    during the production shift

4
Business improvement objectives
Establish a relationship between Performance
Measures and Business Objectives and to reduce
  • Waste / Rejects
  • Increase Production Yield
  • Improve Variability Control
  • Rework
  • Improve Production Quality
  • Maintenance Costs
  • Increase Plant Availability
  • Increase Maintenance Efficiency
  • Downtime and Rate Loss
  • Improve OEE
  • Increase Asset Utilization
  • Operational Costs
  • Increase plant reliability
  • Increase equipment utilization
  • Increase Energy Efficiency
  • Increase Labor Efficiency

5
What is OEE?
6
What is OEE?
  • Overall Equipment Effectiveness
  • A measure of how healthy your production process
    is relative to your planned production schedule
  • A Standard Metric for Production Loss

Introduction to TPM by Seiichi Nakajima,
Productivity Press, Cambridge, MA
7
Simple OEE
  • Time Loss
  • Rate Loss
  • Quality Loss

8
Component OEE
OEE Availability x Performance x Quality
9
Ampla Performance Applications
10
User interface
The Plant Tree
Filter Pane
Module Toolbar
Data Grid
Charting Toolbar
Charting Pane
11
Smart KPIs
  • KPI Attributes
  • Current Value
  • Target ( Budget)
  • Status
  • Thresholds
  • Trends

Trend
Target
Thresholds
Current Value
Thresholds
History
12
Ampla Metrics - Dashboard
13
Metrics Analysis
  • Alternative to Dashboard View
  • Period Selection and Drill In
  • Threshold Highlighting
  • SPC Charts

14
Ampla Metrics Analysis
15
Enterprise Dashboards
  • Allows a single dashboard to host controls
    sourcing Metrics data from multiple servers
  • Data via Web Service
  • Facilitates hosting Metrics controls in external
    intranet pages

16
Ampla Downtime
  • Captures all occurrences when the plant is not
    producing or producing below target rate/quality
  • Automatically determine a Production Loss
    condition
  • Capture Real downtime (zero production)
  • And Virtual downtime (rate or cycle time loss)
  • Auto or Manual capture of
  • Cause and Effect of Downtime
  • the Location of the cause
  • the Classification of the cause

17
Ampla Downtime
18
Ampla Production
  • Captures all quantity-related data
  • Automatic or manual input
  • Can apply complex equations
  • Totalizes or time-based data set
  • Categorizes data for reporting
  • Input, Consumables, Waste, Output, Reject,
    Product
  • Simple Mass Balance
  • Production Accounting
  • ID fields to enhance analysis

19
Trend Projection Example
Before
and after
20
Ampla Production Enhanced Analysis
  • All Production Charts
  • For Comparative Analysis of Production
    Performance
  • analyze by any Filterable Field
  • Chart Together or Separately
  • By Analysis Field Value
  • By Field Units

21
Ampla Production Enhanced Analysis
22
Why Manufacturers Choose Citects Ampla solution

23
Quick facts about Citect
  • Founded in 1973
  • Over 6,000 active customers and 100,000
    installations worldwide
  • Global customers who have implemented Ampla
    solutions
  • Energizer
  • Mitsubishi
  • Sara Lee
  • CONSOL Energy
  • WMC
  • Fastest growing industrial software vendor in the
    Americas

24
Citect real-time intelligence product suite
25
Ampla aligns manufacturers with new plant
realities
  • Increase Overall Plant Efficiency (OPE) through
    advanced software tools
  • High level of integration between operations and
    the business suite to increase ROA
  • KPI-oriented analysis to simplify decision making
  • Detection of root causes over long periods of
    time
  • Optimization of work flow based on quantified and
    measured results

26
Align personnel and supply issues
  • Analyze efficiency down to individuals and crews
  • Track and analyze production, quality, downtime
    and production costs in real time
  • Executives and workers can make timely decisions
    in reaction to poor production performance and
    quality problems

27
Questions?
Thank You! Please visit us at booth 1213
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