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Manufacturing Execution Manufacturing Execution SystemsSystems

Achieving high efficiency and traceability in Achieving high efficiency and traceability in film manufacturingfilm manufacturing

Wolfgang ZintzWolfgang ZintzBrBrüückner ckner ServtecServtec GmbHGmbH

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Manufacturing Execution Systems

Highlights

Definition

How to Measure

How to Improve

What You Get

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Highlights

Maximise Throughput

Gain Flexibility (Production Control)

Reduce Stock

Reduce Maintenance Cost

Guarantee Traceability

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Manufacturing Execution Systems

Highlights

Definition

How to Measure

How to Improve

What You Get

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What is MES?

Manufacturing Management System MMS

ISA Level

4

3

2

1

0

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MMS Integration

Entire ProductionProcess

Multiple Sites

Various Suppliers

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Existing Solutions

Paper Interface?

Standalone Systems?

Integrated Solution?

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Existing Solutions

NewStandard

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Manufacturing Management Systems

Highlights

Definition

How to Measure

How to Improve

What You Get

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How to Measure

Online Data (Process)●Real Time

●Long Term

●Roll Related

●One System

Offline Data (Lab) ●Mill Rolls/Slit Rolls

●Specification Check

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Tracking & Analysis

Raw Material Balances

KPI in Real Time(Key Performance Indicator)

… all per mouse click !

How to Measure

Data Information Best Decision

3%1%

96%

Production Startup Filmbreak

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Key Performance Indicators

Production Time [h]Availability = Total Time [h]

UnplannedDowntime

PlannedDowntime

SetupTime

Total Time [h]

Production Time [h]

Actual Throughput [kg/h] Performance = Nominal Throughput [kg/h]

Process & MachineProblemsActual Throughput [kg/h]

Nominal Throughput [kg/h]

Good Film [kg]Quality =Material Consumption [kg]

Edge TrimYield

Material Consumption [kg]

Good Film [kg]B-GradeRejects

Overall Equipment Effectiveness OEE= A x P x Q [%]

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OEE Example

TypicalResults

95%

95%

93 %Production Time [h]Availability =Total Time [h]

Actual Throughput [kg/h] Performance =Nominal Throughput [kg/h]

Good Film [kg]Quality =Material Consumption [kg]

OEE [%] = 93 x 95 x 95 = 83,9%

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Manufacturing Management Systems

Highlights

Definition

How to Measure

How to Improve

What You Get

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How to Improve

Planning and Scheduling

CUT Optimisation

Maintenance System

MMS = Flexibility, ThroughputLess Stock, Delivery Time

… all per mouse click !

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Manufacturing Management Systems

Highlights

Definition

How to Measure

How to Improve

What You Get

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What You Get

“Total Integration”

Next Level Technology

Focus change Operative Strategic

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What You Get

You Save ●Set-up time●Change-over waste● InventoryYou Improve●Product to market timeYou Gain● Increased market share

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Manufacturing Management Systems

“The only constant in the universe is change”

Thank You!