Title: ImprovingProductivity and OEE Utilizing RealTime Manufacturing Intelligence Solutions
1Improving Productivity and OEE Utilizing
Real-Time Manufacturing Intelligence Solutions
- How is your plant performing?
John Cavalenes Director of MES Solutions Citect
Americas
2Recent 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
3How 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
4Business 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
5What is OEE?
6What 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
7Simple OEE
- Time Loss
- Rate Loss
- Quality Loss
8Component OEE
OEE Availability x Performance x Quality
9 Ampla Performance Applications
10User interface
The Plant Tree
Filter Pane
Module Toolbar
Data Grid
Charting Toolbar
Charting Pane
11Smart KPIs
- KPI Attributes
- Current Value
- Target ( Budget)
- Status
- Thresholds
- Trends
Trend
Target
Thresholds
Current Value
Thresholds
History
12Ampla Metrics - Dashboard
13Metrics Analysis
- Alternative to Dashboard View
- Period Selection and Drill In
- Threshold Highlighting
- SPC Charts
14Ampla Metrics Analysis
15Enterprise 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
16Ampla 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
17Ampla Downtime
18Ampla 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
19Trend Projection Example
Before
and after
20Ampla 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
21Ampla Production Enhanced Analysis
22Why Manufacturers Choose Citects Ampla solution
23Quick 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
24Citect real-time intelligence product suite
25Ampla 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
26Align 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
27Questions?
Thank You! Please visit us at booth 1213