Lead by TRUE OEE - HASMAK Paper.pdf · 2015-01-26 · World-Class Shop Floor Management Lead by...
Transcript of Lead by TRUE OEE - HASMAK Paper.pdf · 2015-01-26 · World-Class Shop Floor Management Lead by...
World-Class Shop Floor Management
Lead by TRUE OEE
FORCAM, Inc.
250 E. Fifth Street, 15th Floor
Cincinnati, OH 45202
(513) 878-2780
www.forcam.com
White Paper
Availability Performance Quality
TRUE OEE
TRUE OEE 3
Planned versus Actual 4
Recipe for Success 5
CIP Organization 6
CIP Communication 7
Shop Floor Control Panel 8
Factory 2.0 9
SFM Technology 10
About FORCAM 12
Customers’ Success Stories 15
Contents
© FORCAM 2013 www.forcam.com Lead by True OEE 2
TRUE OEE
FORCAM provides an innovative production software technology (Factory Framework™) and
consults on state-of-the-art Shop Floor Management. World-class companies from diverse
manufacturing sectors like automotive, machinery, aerospace, medical engineering and
packaging are utilizing FORCAM’s Shop Floor Management solution. It enables companies to
measure performance of their machines and plants in real-time to quickly recognize and
correct errors and waste, and to continuously optimize their productivity.
Shop Floor Management principles are the
foundation for “True OEE” 1. Leadership Principle Shop Floor Management is a top-down process. Management must be trained to incorporate
the CIP culture and to lead by OEE.
© FORCAM 2013 www.forcam.com Lead by True OEE 3
2. Management Tool ERP systems are not suited to support the CIP organization. Real time ERP data
combined with machine data is required to visualize the real status of the shop floor and to
calculate a TRUE OEE. Planned vs. Actual Performance Analysis is the key element of
Shop Floor Management.
Planned vs. Actual
The Lean Philosophy empowers the shop floor operator. The operator needs to know what
the supply chain (ERP) expects from him such as when to start an order/operation and
what target must be fulfiled.
Planned vs. Actual performance information in real time will give the operator immediate
feedback about the current performance of his manufacturing workplace in order to take
immediate measures in the case of a deviation from target.
How do you measure your shop floor performance today?
- Are there deviations between your planned setup versus actual setup times?
- Are there deviations between your planned cycle versus actual cycle times?
- How do you track and measure planned quantity deviations from actual quantity yield?
True OEE is driven by Planned vs. Actual
performance information collected in real time
© FORCAM 2013 www.forcam.com Lead by True OEE 4
Recipe for Success
With the help of FORCAM, elite companies have been able to increase productivity measured
with TRUE OEE by up to 20% within the first year.
The Recipe for Success - holistic Shop Floor Management that effectively combines the most
advanced Shop Floor Management System with the Lean Management philosophy.
A Recipe for Success in Shop Floor Management:
Measuring TRUE OEE - what you cannot measure you cannot improve
Adopting Lean Management principles and leading by OEE
Creating a Continuous Improvement Process (CIP) culture with closed-loop communication
Delivering the right information to right people at the right time
Delivering planned vs. actual performance information real-time to shop floor operators
Establishing a PDCA (Plan-Do-Check-Act) cycle with actions and measures
Setting regular TRUE OEE goals for continuous improvement
FORCAM Guarantees 10% Increase in Productivity
© FORCAM 2013 www.forcam.com Lead by True OEE 5
CIP Organization
All manufacturing roles are supported by advanced shop floor management
technology with no exceptions, from the machine operator to maintenance to
the plant manager.
Advanced Shop Floor Management (SFM)
technology must support all organizational roles
within the CIP Organization.
© FORCAM 2013 www.forcam.com Lead by True OEE 6
Continuous Improvement Process (CIP) Organization
CIP Communication
Advanced Shop Floor Management (SFM) technology
offers closed loop CIP communication by delivering the
right information to the right role at the right time
Periodic CIP Meetings, weekly and monthly, will utilize real time Shop Floor
data to monitor, analyze, and set goals and targets for:
Stoppages / Downtimes
Production Flow
Organization
Quality
Tools Optimizations
Logistics
Worker Orders / Routing
Current Turnaround / Productivity Values
© FORCAM 2013 www.forcam.com Lead by True OEE 7
Shop Floor Control Panel
(Sample from Audi)
© FORCAM 2013 www.forcam.com Lead by True OEE 8
Factory 2.0
Measuring and optimizing the performance
of manufacturing plants anywhere, anytime
The real-time information provided by FORCAM can be accessed through mobile gadgets including smartphones and tablets.
iFactory mobile application is now available.
Planning and Production are now synchronized
“Today, companies need resource efficiency in processes and in manufacturing.”
FORCAM’s Chairman, Franz Gruber, states. Everything has to intertwine in a way that errors and waste can be recognized immediately and eliminated sustainably.
The FORCAM technology complements standard ERP-software on the planning level (top floor) using objective performance data coming directly from all factory assets (shop floor) – from one single machine to multiple plants worldwide. The efficiency factor of standard ERP-software is enhanced due to the real-time data capture by FORCAM. Simultaneously, FORCAM enables customers to apply the technology themselves in their company following a pilot phase.
FactoryFramework™ Shop Floor Management System
Advanced Shop Floor Management
Creates The Transparent Factory
© FORCAM 2013 www.forcam.com Lead by True OEE 9
Management OEE Dashboard
Operator Planned vs. Actual
Maintenance Pareto Hit List
Plant Manager Live Web Visualization
SFM Technology (1/2)
State-Of-The-Art Shop Floor Management
Flexible web-based connectivity of a diverse number of machine controls
FORCAM‘s Factory Framework™ solution is technologically leading Manufacturing Execution System (MES). It enables improvement processes on all levels of the production. Factory Framework™ connects, collects, and standardizes real-time data from most different machine controls. For every production level, the signals provide comparable web-based operational states of machines and plants (production, malfunctions, and downtimes).
Result: Transparent and reliable performance data – runtime, speed, quality. Additionally, Factory Framework™ connects production data with ERP data from corporate planning such as targets for orders and resources.
From the operator to the manager
All roles involved are able to
continuously optimize productivity
within their role.
Leading-edge Technology: Complex Event Processing (CEP) with Live Cache
FORCAM uses Complex Event Processing (CEP) with Live Cache, a technology used for real-time analysis of event stream from the financial sector. FORCAM combines CEP with the proven and tested MES in a rule-based approach in an optimal way.
Results:
• Fast reaction with latencies in the millisecond range and high throughput (factor is 100 times higher than in the past product generation)
• Rule-based approach enables flexible, user-defined functions
• Global deployment potential with Unicode language support and centralized server architecture
© FORCAM 2013 www.forcam.com Lead by True OEE 10
SFM Technology (2/2)
Overall Equipment Effectiveness (OEE) is Optimized
OEE - Overall Equipment Effectiveness
Shop Floor Management (SFM) is a strategy designed for the continuous optimization of the plant availability by eliminating errors and waste. The most important key figure to measure the performance is the OEE – Overall Equipment Effectiveness.
As key performance indicator, OEE results from three performance data which FORCAM monitors and visualizes in real-time, and therefore available anywhere and at any time:
How long has it been producing?
How fast has it produced?
How well has it produced?
OEE is the most important key figure (KPI) to implement the SFM strategy.
OEE is the measure for the added value of a machine.
OEE visualizes exactly which machine and process losses can be minimized.
OEE - Three crucial performance metrics: Availability, Productivity, Quality
OEE
TimeQ 4 Q 3 Q 2 Q 1
Point of the symbiosis
Lean Management Organisation
and technology
© FORCAM 2013 www.forcam.com Lead by True OEE 11
FORCAM – At a Glance
FORCAM Guarantees up to
20 % Higher Productivity in Factories in
Less Than 1 Year
MARKET Discrete Manufacturing Industries
- Automotive
- Aerospace & Defense
- Medical Devices
- Machinery
- Oil & Gas
PRODUCT Shop Floor Management System
TECHNOLOGY Leading-Edge Manufacturing Execution System FactoryFramework™
CUSTOMERS Vertical Market Segments (Automotive/Aerospace/Medical)
Select Customers include: Audi, BMW, Daimler, BorgWarner, MTU Aero Engines, Mann+Hummel, P&H Mining, WEIR Minerals
IMPACT > Significant improvements in productivity (up to 20%)
> Accelerated Return on Investment (ROI 1 Year)
> Optimized Return on Capital Employed (ROCE)
> Improved transparency leading to lower costs
> Higher energy and resource efficiency
MANAGEMENT > Former SAP Executive founded FORCAM in 2001
> SAP co-founder, Dietmar Hopp is a FORCAM stakeholder
SELECT PARTNERS > SAP
> IBM | TDM Systems | Q-DAS
> IMS Center, University of Cincinnati (Prof. Jay Lee)
> Massachusetts Institute of Technology - MIT (Prof. Bühler)
© FORCAM 2013 www.forcam.com Lead by True OEE 12
2001 + Foundation (SAP Spin-off to close the gap between Top-Floor and Shop-Floor )
+ Development of the first web-based Thin-Client production software
2002 + Daimler Powertrain Plants – development partnership to deploy thin-client web
technology to the shop-floor.
2003 + Kuka Robots – Seamless integration with SAP
+ Strategic partnership with IBM
2004 + Daimler Press Plants – 3 Press Plants with Assets worth 2.5 Billion Dollars
2005 + FORCAM rejects a bid by SAP AG
+ SAP co-founder Dietmar Hopp acquires a 10% share
2006 + Baden-Württemberg Innovation Award to FORCAM awarded for their vision and outstanding ability to execute for Daimler Powertrain Project
2007 + Breakthrough: Global Roll-out at Schaeffler Technologies and Mann+Hummel
(with Seamless SAP Integration)
2008 + Breakthrough: AUDI and BMW Press Plants opt for FORCAM
+ Daimler engine plant in Untertürkheim becomes Factory of the Year
2009 + AUDI stamping plants increase productivity by 20% within 12 months
+ On the way to set the TPM industry-standard in pressing plants
2010 + SEW (France) achieves a productivity increase by 20% in just 3 months
+ SAP co-founder Dietmar Hopp increases share to 17%
+ Founding of FORCAM Ltd in the United Kingdom
+ FORCAM initiates Research Partnership with Prof. Jay Lee at the Center for Intelligent Maintenance Systems (IMS) in University of Cincinnati, USA.
2011 + FORCAM’s Annual Customer Event (FIT 2011) hosted by Audi in Ingolstadt
+ WEIR Minerals (UK) reports 12% raise in efficiency in 6 months
+ New Customers in the USA: ZF, P&H Mining, Coperion, LUK Wooster
+ Installation of Service and Support Center in Hungary
2012 + FORCAM’s Annual Customer Event (FIT 2012) hosted by Daimler (Mercedez-Benz)
+ German Government awards FORCAM the SMB Innovation Award
+ ARC nominates FORCAM Customer, BorgWarner, for Best-in-class Shop Floor Management.
+ Founding of FORCAM INC. based in Cincinnati, Ohio, USA
Milestones
© FORCAM 2013 www.forcam.com Lead by True OEE 13
Management
Franz E. Gruber Founder & Chief Executive Officer (CEO)
Industrial Engineer
Since 2001: President and Chairman FORCAM
Until 2001: SAP AG
(Sales Executive, Special Functions for SAP CEO)
1989: Trainee IBM
CIM (Computer Integrated Manufacturing) Consultant
1988: Degree Fachhochschule für Technik (Advanced
Technical College), Esslingen
Dr. Mohamed AbuAli Chief Operating Officer (COO)
Manages delivery and deployment of FORCAM‘s technology
Ph.D. Industrial Engineering – University of Cincinnati
Project Management Professional (PMP)
Certified Quality Engineer (CQE)
Advisory Board
Erich Bühler
Former Daimler-Benz AG
Professor Dr. Dietmar Kilian
Corporate consultant, former SAP AG
Kurt Striedacher
Founder Kumatronik Group
Berthold Wipfler
SAP AG
© FORCAM 2012 www.forcam.com Lead by True OEE 14
Success Stories
• Daimler (Mercedes-Benz)
• Factory of the Year Award (by A.T. Kearney)
• Delivering monitoring and optimization of more than 14,000 machine tools
• Audi
• Audi Stamping Plants + 20% increase in TRUE OEE within 12 months
• Audi Components Plants + 10% increase in TRUE OEE within 12 months
• Click Here for Audi Case Study
“Due to Factory Framework, the press plants at Audi have increased productivity by 20
percent. Investing in a new software architecture was well worth it.”
Axel Bienhaus - Audi AG
• BorgWarner
• Exceeding expectations with unique shop floor management strategy
• 4.3% increase in TRUE OEE within 6 months
• Click Here for BorgWarner Case Study (presented at ARC Industry Forum 2012)
• Weir Minerals
• 12% increase in TRUE OEE within 6 months
• Click Here for Weir Minerals Case Study
FORCAM offers you a unique solution, based on the Lean Manufacturing Philosophy
of how to successfully manage and operate manufacturing facilities.
“FORCAM will bring True OEE to your company.”
With FORCAM technology, elite companies have increased productivity
by up to 20% within the first year, measured by
TRUE Overall Equipment Effectiveness (OEE).
© FORCAM 2013 www.forcam.com Lead by True OEE 15
Copyright © 2013 FORCAM Unauthorized use or reproduction of this work is in any form is prohibited
FORCAM, Inc.
250 E. Fifth Street, 15th Floor
Cincinnati, OH 45202
(513) 878-2780
www.forcam.com