PRODUCTIVITY IMPROVEMENTS COME AS STANDARD Make an IMPACT with OEE! Section 1: What is OEE Section...
Transcript of PRODUCTIVITY IMPROVEMENTS COME AS STANDARD Make an IMPACT with OEE! Section 1: What is OEE Section...
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Make an IMPACT with OEE!
Section 1: What is OEESection 1: What is OEE
Section 2: OEE IMPACT Software + ConnectSection 2: OEE IMPACT Software + Connect
By: Gemba Solutions Ltd - Designer & Manufacturer Control Dynamics, Inc – Distributor & Integration Partner
Bringing to you OEE LEAN IMPACT Software Products
Productivity Improvements Come as Standard
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Using OEE Impact Software will revolutionize the way in which you collect and analyze your manufacturing shop-floor data. its feature-rich functionality and easy to use interface enabling you to save countless man-hours over your current methods of collecting and analyzing machine performance data and bottlenecks.
OEE IMPACT has been specifically designed around the industry accepted and proven OEE Calculation standard and includes all the tools you need to measure and Impact your productivity and capacity.
However, OEE Impact goes a step further in providing a host of additional features compared to a standard OEE based solution. From the experience we have gained over many years, we have logically extended OEE IMPACT to incorporate valuable capabilities to allow the collection and analysis of virtually any efficiency data, such as: Machine / Line Set-up Time; Product Analysis; Scrap / Rejects; Re-work; Maintenance Times; etc..
It doesn’t stop there. OEE IMPACT is fully scalable and can be expanded with a number of add-on modules, including the automatic collection of data in real-time from your shop-floor assets. As a part of the LEAN Impact Suite of products OEE IMPACT will give you confidence that it will never be outgrown, making OEE IMPACT an invaluable tool now and into the future with which to manage your business.
We guarantee that OEE IMPACT will become a key component in your productivity toolbox, enabling you to get to grips with an impact:
• Machine cycle time• Machine availability• Downtime • Utilisation• Throughput• Shop Floor losses• Maintenance performance• Product performance• Mean time between failures• Bottle neck identification• Production and shift performance• Improve capacity planning• Wastage / Scrap / Rejects Analysis• Plus much, much more……..
Don’t just take our word for it. Ask for a ‘fully featured’ free trial of OEE IMPACT product today and see what your OEE figures really are.
Introduction
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Key Performance Indicators
• Machine cycle times• Machine availability• Downtime • Utilization• Throughput• Shop-floor losses• Maintenance performance• Product performance• Meantime between failures• Bottleneck identification• Production and shift performance• Target capacity planning• Waste / Scrap / Rejects• Plus much, much more……..
Don’t take our word for it - ask for the ‘fully-featured’ demo of OEE IMPACT today and see what your OEE figures really are!
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
If you don’t measure how can you hope to manage it?If you don’t measure how can you hope to manage it?
What is OEE
The Calculation:
OEE% = Availability % x Performance% x Quality%
where:
Availability % = actual running time / planned cell production time Performance% = pieces produced / the theoretical cell production
rateQuality % = good pieces / total pieces made
No matter what type of process or manufacturing operation you are involved in and regardless of your company size you are likely to be under constant pressure to improve performance, improve quality and increase equipment availability.
Targeting any one of these three key areas for improvement, availability, performance or quality, may seem a major task and addressing all three together may seem a daunting task. However, if these areas can be addressed simultaneously, then significant improvements can be made throughout the production process. Production Output can be increased, Product Variations can be expanded and Production Cost Reductions can be achieved.
A good starting-point in attempting to achieve this is to identify and focus on simple but effective areas of the efficiency tree, areas such as asset (machine) performance which is always a hot topic. This is where OEE Analysis (Overall Equipment Effectiveness) can really help to make a difference to your productivity decision-making on a day-to-day basis.
OEE is a simple but clever calculation which focuses on individual items of process or manufacturing equipment at a finite level and allows their ‘effectiveness’ to be measured individually or in groups (i.e. with other equipment items). The OEE calculation is based on the ratio of the three key production parameters, availability, performance, and quality with time (e.g. planned shift time/s) being used as the baseline measurement.
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
What is OEE
OEE = Availability (B/A) X Performance (D/C) X Quality (F/E)
Planned Shift
A Planned Machine Production Time
B Actual Running Time
C Theoretical Machine Production Rate
D Actual Production Rate
E Pieces Produced
F Good Parts
Idle Time
Down Time
Speed Loss
Scrap / Rejects
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Measuring OEE
• Simple system (can be achieved with manual data collection and entry system)Simple system (can be achieved with manual data collection and entry system)– Machine Status (Running or Stopped)
– Product Count
– Quality Rejects
– Simple stoppage reasons (Critical, Moderate, Non-Critical)
– Cost Effective way to produce and distribute reports to plant personnel
• More advanced (usually achieved with automated data collection system) More advanced (usually achieved with automated data collection system) – Machine Status (Running or Stopped)
– Product Count / Rates
– Quality / Rejects
– Asset Grouping
– Event Line Viewers / Dashboards
– Job Planning / Queuing / Dispatch
– Advanced Security
– Multiple Downtime Reasons categories
– HR / Machine Operator Tracking
• Why not consider a “mix & match” methodWhy not consider a “mix & match” method– Manual Data entry and Automated Collection!
– Start Small but THINK BIG Scalability
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Start small but Think Big = scalability
• Manual Data CollectionManual Data Collection– Collect the data through paperwork entry forms filled in by operators
– Replace Excel or Access Software Solutions
– Analyse with OEE IMPACT
• Manual and/or Automated Data collectionManual and/or Automated Data collection– Install OEE IMPACT Connect and collect data automatically from assets.
– Analyse with OEE IMPACT in real time and Historically
Here is an example of how it would works:Here is an example of how it would works:
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
How OEE IMPACT Works (manual data collection)
Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators.
Configure OEE IMPACT (one time only)
Shop floor operators fill in production data forms as required.
Keyboard Production Data from Forms into OEE IMPACT Reports at anytime and/or up-date historical records as needed.
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
How OEE IMPACT Works (manual + Automated data collection)
Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators.
Shop floor operators fill in production data forms as required.
Configure OEE IMPACT (once only)
Input Data from Production data forms into OEE IMPACT Reports
OEE IMPACT Powerful automated reporting tool with over 200 standard reports allows easy analysis of OEE data and much more…
Automated Data Collection into OEE IMPACT Server.
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Typical OEE IMPACT Connect
Ethernet+ Wi-Fi / RS485
OEE IMPACT DCT
OEE IMPACT Clients
Open Data Interface Input Data to OEE IMPACT through CSV Interface from (ERP, SCADA, DCS, Excel, SQL etc..)
Manual
Third Party InterfaceSpecific software data interfaces to SQL, OPC, SCADA, ERP, CMMS and many other interfaces to collect operational data required for OEE IMPACT data logging
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OEE IMPACT Connect DCT
• OEE IMPACT CONNECT D.C.T (Data Connection OEE IMPACT CONNECT D.C.T (Data Connection Terminal)Terminal)– Price for features delivered leader in market place– Features
• Ethernet (Wi-Fi)
• Up to two serial ports (barcode reader HR Cards, RF ID etc..)
• Outputs
• Mains powered
• Compact
• Easy to configure
• Internal I/O power supply (24v)
• Expandable with data logging
• Compact design
• Can be used with LEAN IMPACT MES Systems
– Hardware Connectivity PLC’s PC’s OPC
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Manual Data Entry Form
Selecting the data
entry screen
Entering scheduled downtime
OEE IMPACT will track production
runs, not just machine
performance
Production information
Downtime reasons
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Production Performance
Selecting the shift
effectiveness Tab
Diagram of production
losses
Final effective production
time
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Shift OEE
Shift OEE performance
OEE Summary
Production Units
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Reporting Tool
• Over 200 pre-defined reports as standard• Total flexibility on reporting
– Graphical charts– Text reports
• Fast data retrieval• Export data to nearly any file or program type
– Get reports that drop into Word or Excel
• Send reports to printers, via emails and through other mediums.
The following slides provide an overview of the power offered by OEE IMPACT’s comprehensive reporting tool.
If you want to try OEE IMPACT for a limited time free of charge contact our sales team and ask for your trial copy - then you can see the true power of OEE IMPACT Reporting…
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Report Generator
Selection of report type
Report Filter provides the
facility to simply drill down into the information
Selection of display options: trends, bar graphs, data grids,
units of display.Group data by Machine, shift,
product, operator Open and save commonly used
reports
Display reports in
3D
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Downtime Summary
Downtime Histogram: All charts
can be user-configured
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Downtime Components
Downtime can be grouped
into categories of your choice
Machine 3 has a high Idle time
Equipment failure accounts for most of
the downtime. Could be time for a planned
maintenance program!
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Downtime Trend
Auto Scaling
Axis
Trend of downtime over time
Use Zoom to see more
detail
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Machine Failure
Identify failure-time
per machine
Failures can be displayed as number of failures, duration, average
duration, time between
failures, MTBF, MTTR….
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Simple Reject Report
Show rejects per machine by
type. OEE IMPACT allows
for as many reject types as
you need.
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
OEE Components
OEE IMPACT provides a vast array of tools for analysing OEE,
this being a starting point
The components
of OEE
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OEE for all Machines
Most Effective Machine
Machine 6 should be
identified for a production
improvement project
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OEE Time Trend
Quickly see trends and short-term problems
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OEE Grid View
A Unique view of OEE
generated by OEE IMPACT
Rapidly identify production hot
spots
A grouping of poor performance on a
particular day
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Production Performance
This chart shows a clear trend of falling
output
Identify the relationship of good parts to bad. Drive a
first-time-right campaign
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Data Grid
All charts will flip to display the raw data.
This data can be simply cut into other
application
Sort the data on the TAB headings
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Chart Editor
With the Chart Editortool you can configure and change the appearance of
the report. ADD extra analysis points; trends, averages. Import external
data
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Report Summary
• In this short presentation you have seen a fraction of what the OEE IMPACT reporting tool has to offer.
• With over 200 report formats to choose from OEE IMPACT has the report you need, from simple text summary reports to complex multi-display 3D/2D charts on the same screen.
• Identify major problems quickly and use OEE IMPACT’s report generator to drill down onto the major issues.
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Real Time OEE
•Enhanced Security
•Real Time Data Capture
•Production Schedules
•Real Time User Configurable Graphics
•Time Line Event Viewer
•Operator Asset Dash Board
•Data import from XML files
•Third Party Interface
•OEE Asset Grouping for lines , cells, areas, etc
•Unlimited free network users
•OEE IMPACT Data Collection Terminals DCT
The Following slides show a sample of the many expanded functions and features you get in OEE IMPACT CONNECT
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Real Time Graphics
Real Time Graphics Viewer from extended menu options in OEE IMPACT CONNECT
Selectable Cell/Line production
performance Figures including OEE
Page displays are configured in 30% of the time of SCADA
systems
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Line & Cell Production
Line Based Production
Cell Based OEE and
Performance Monitoring
Production trends showing in real time
as changes in today's production allowing
rapid responses
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Performance Summary
Real-time OEE and Production Displays.
Red and Yellow levels of warnings
Real Time Pareto Charts
Ability to Manually Enter Downtimes and
Events
Three OEE Outputs•Shift performance to date•Performance of all jobs to date•Current Job
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Event Viewer
Review •Manual•Scheduled•Automatic
EventsSpot Bottle NecksCycle TimesOperator Actions
With the correct security levels
modify recorded events
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Production Schedules
Create Production Schedules for the day and allocate the Jobs to
machines, cells and lines.
Plan usingOperations and Routes for you
individual product standards
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
OEEIMPACT
OEE IMPACT Server (MSDE)
OEE IMPACT Connect
OEE IMPACTOEE IMPACTProduct ModulesProduct Modules
Gemba Solutions Software Product Range
LEAN IMPACT Server (SQL)
Full HR Tracking
Batch Recording
Product Tracking
Recipe Handling
Enhanced OEE
Trending
OPC
ERP Interface
+ Others
Additional LEAN IMPACT Products
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Hardware & Software Requirements
• OEE IMPACT minimum recommended PC requirements:
– Software Recommended• Windows 2000 or XP (latest service packs)
– Minimum Hardware• PIII 800 or equivalent• 500 Mbyte hard disk space free• 64 Mbyte RAM• 1024x768 32 bit graphics card and monitor (preferred)• Network card (for multi-user configuration)
Please check with our technical sales team for up to date requirements.
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
• Price starts from only $2,995.00Price starts from only $2,995.00• Full product demonstration available.Full product demonstration available.• Manual and Real-time SolutionsManual and Real-time Solutions• Eliminate custom-built Access and Excel systems.Eliminate custom-built Access and Excel systems.• Unlimited network users (client Interface) included Unlimited network users (client Interface) included
in the price as standard.in the price as standard.• Over 200 standard reports included, together with a Over 200 standard reports included, together with a
custom report builder.custom report builder.• Easy to install, configure and use.Easy to install, configure and use.• Provides full standard OEE data entry and Provides full standard OEE data entry and
reporting as well as the ability to report OEE on reporting as well as the ability to report OEE on labor, shifts, products and much more…..labor, shifts, products and much more…..
• Understand downtime, set-up, Scrap / Rejects, Idle Understand downtime, set-up, Scrap / Rejects, Idle time, Meantime Between Failure (MTBF) + more….time, Meantime Between Failure (MTBF) + more….
• Expandable and scalable to fully features LEAN Expandable and scalable to fully features LEAN IMPACT MES System.IMPACT MES System.
• Full web and telephone support service.Full web and telephone support service.• OEE IMPACT training courses available at CDI or OEE IMPACT training courses available at CDI or
on-site at your facility.on-site at your facility.
Summary
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Here is what people are saying about OEE IMPACT:Here is what people are saying about OEE IMPACT:
• “Not just another toolkit to see data”• “Configuration is easy and intuitive”.• “Data entry is a delight to use”.• “The reporting and analysis tool allows instant and outstandingly flexible reporting”• “Installation was simple and required no additional software”.• “The cost against the functions you get in OEE IMPACT are amazing”.• “Gemba Solutions have a real winner in OEE IMPACT”.• “Five network nodes ‘as standard’ allows exceptional flexibility”.• “Knowing OEE IMPACT is part of the CATS IMPACT MES Suite is a bonus”.• “OEE IMPACT is the most advanced OEE Management Software on the market”.• “Starting at $2995 this is real value for money, how does Gemba do it?”• “Well done Gemba Solutions for yet another really useful software product”.• “OEE IMPACT paid for itself in less than 2 months!”
What People Say
PRODUCTIVITY IMPROVEMENTS COME AS STANDARD
Make a Difference
Thank you for your time and for the opportunity !
Call our Sales team to be rushed your own fully featured OEE IMPACT Product today on the number below or request it from our web site at:
Control Dynamics, Inc.4246 Corporate Exchange DriveHudsonville, MI 49426(616) 896-2008www.cdi-mi.com
Garry Muma Mike BridleProductivity Sales Engineer (616) 896-2032 (616) 896-2030