World Class Manufacturing Asset Utilization
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Improving Asset Utilization Improving Asset Utilization The Key to World Class The Key to World Class Manufacturing Manufacturing PROPRIETARY NOTICE The information contained on all pages of this document consists of technical, commercial, and / or financial information which is confidential and proprietary to Woodard & Curran. This information is presented in confidence to our Customer with the understanding that it may not be reproduced or used, in whole or in part, for any purpose other than evaluation of the services described herein.
description
This is a program that we can offer to improve your operations.
Transcript of World Class Manufacturing Asset Utilization
Improving Asset UtilizationImproving Asset Utilization
The Key to World ClassThe Key to World ClassManufacturingManufacturing
PROPRIETARY NOTICE
The information contained on all pages of this document consists of technical, commercial, and / or financial information which isconfidential and proprietary to Woodard & Curran. This information is presented in confidence to our Customer with the understanding thatit may not be reproduced or used, in whole or in part, for any purpose other than evaluation of the services described herein.
Our ObjectiveOur Objective
Woodard & Curran values this beverage client asWoodard & Curran values this beverage client asa major strategic client.a major strategic client.
We want to be the consultant of choice inWe want to be the consultant of choice inengineering services.engineering services.
Assist client in their path toward a moreAssist client in their path toward a morecompetitive, worldcompetitive, world--class, efficiencyclass, efficiency--driven, agile & growthdriven, agile & growth--oriented supplyoriented supply
chain networkchain network
Focus on ManufacturingFocus on ManufacturingPerformancePerformance
Methodology Parameters:Methodology Parameters:–– Measures effectiveness of an assetMeasures effectiveness of an asset
–– Based on industry standards to compare & benchmarkBased on industry standards to compare & benchmarkbase line metricsbase line metrics
–– Repeatable and consistentRepeatable and consistent
–– Flexible and scalableFlexible and scalable
–– Based upon an open technologyBased upon an open technology
Metric to be used is:Metric to be used is:
Overall Equipment Effectiveness (OEE)Overall Equipment Effectiveness (OEE)
How is OEE derived?How is OEE derived?
Single ShiftSingle Shift
Lunch BreaksLunch Breaks
MeetingsMeetingsAvailable TimeAvailable Time
Sto
psS
tops
Overall Equipment Effectiveness =Availability x Performance x Quality(EA) x (PE) x (QR)
Overall Equipment Effectiveness =Availability x Performance x Quality(EA) x (PE) x (QR)
Availability = Available Time – Down TimeAvailable Time
Availability = Available Time – Down TimeAvailable Time
Equipment FailureEquipment Failure
Setup & AdjustmentSetup & AdjustmentRun TimeRun Time
Dow
nT
ime
Dow
nT
ime
Reduced SpeedReduced Speed
Idling & Minor StopsIdling & Minor StopsFull CapacityFull Capacity
Spe
edLo
sses
Spe
edLo
sses
Performance = ProductionRated Speed x Run Time
Performance = ProductionRated Speed x Run Time
Quality = Production -RejectsProduction
Quality = Production -RejectsProduction
RejectsRejects
Reduced YieldReduced Yield
GoodProduction
GoodProduction
Rej
ects
Rej
ects
Time Example Time Lost Causes Key Performance Indicators
90.0%90.0%Overall OEEOverall OEE
99.9%99.9%QualityQuality
95.0%95.0%PerformancePerformance
90.0%90.0%AvailabilityAvailability
World ClassWorld ClassOEE FactorOEE Factor
What is the program Woodard &What is the program Woodard &Curran proposes???Curran proposes???
Analyzeequipment data
Implementsolution
Measure OEE
Phase 1: MeasurePhase 1: Measure
Evaluate/upgrade line communicationEvaluate/upgrade line communicationarchitecturearchitecture
Map data in OEM control processorsMap data in OEM control processors
Install data server and concentratorInstall data server and concentrator
Install KPI softwareInstall KPI software
ThenThen …… collect data for three monthscollect data for three months
Quick road to the benefitsQuick road to the benefitsPackaged KPI application?Packaged KPI application?……
Decreased timeDecreased time--toto--deploymentdeployment–– Accelerates payback and ROIAccelerates payback and ROI
Reduced project risk and costReduced project risk and cost–– Well defined scopeWell defined scope
–– Proven, preProven, pre--packaged application functionalitypackaged application functionality
–– Based on extensive domain expertise, knowledge ofBased on extensive domain expertise, knowledge ofmarket best practices, and operational/businessmarket best practices, and operational/businessprocessesprocesses
Sustainability of solutionSustainability of solution–– Packaged software upgraded periodically to stopPackaged software upgraded periodically to stop
technology stagnationtechnology stagnation
Phase 1: DeliverablesPhase 1: Deliverables
Factory Metrics installedFactory Metrics installedon two lineson two lines
Facility controlsFacility controlsarchitecture upgraded andarchitecture upgraded anddocumenteddocumented
Listing of data tables inListing of data tables inOEM equipmentOEM equipment
Phase 2: AnalyzePhase 2: Analyze
Performance affected by:Performance affected by:
–– Line designLine design
–– Equipment reliabilityEquipment reliability
–– Equipment integrationEquipment integration
–– Packaging materialPackaging materialsupplierssuppliers
–– Operator trainingOperator training
–– Plant culture andPlant culture andmanagementmanagement
Phase 2: DeliverablesPhase 2: Deliverables
Recommendations forRecommendations forimprovementimprovement
Prioritize problems toPrioritize problems totackletackle
Contractual options forContractual options forW&C to implementW&C to implementsolutions with possiblesolutions with possibleperformanceperformance
guaranteeguarantee
Phase 3: ImplementPhase 3: Implement
Procure equipment andProcure equipment andcontractors as neededcontractors as needed
Schedule upgrades onSchedule upgrades onplant equipmentplant equipment
Implement additionalImplement additionaltraining as neededtraining as needed
The key to successThe key to success…… ourourPartners in ChangePartners in Change
The Change Management TeamThe Change Management Team
Woodard & CurranProgram Manager
W&C Engineers KPI Software Supplier OEMsOrganization
Training Consultants
Controls Design
Programmers
Packaging Engineers
Primary Packaging Equipment
Secondary Packaging Equipment
Material Suppliers
Next StepsNext Steps
Client selects two target sitesClient selects two target sites
Preliminary Engineering ProposalPreliminary Engineering Proposal–– Evaluate controls architectureEvaluate controls architecture
–– Analyze OEM processor data structureAnalyze OEM processor data structure
Phase 1 and 2: Measure and AnalyzePhase 1 and 2: Measure and Analyze–– Implement necessary control upgradesImplement necessary control upgrades
–– Install Factory MetricsInstall Factory Metrics
–– Collect data and issue reportCollect data and issue report
Phase 3: ImplementPhase 3: Implement–– Implement corrective actionImplement corrective action
