BY THE END OF 2017 ALL FUTURE FACTORIES ARE EXPECTED TO HAVE RS PRODUCTION

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2 ORKLA MANAGEMENT EXPECTATIONS BY THE END OF 2017 ALL FUTURE FACTORIES ARE EXPECTED TO HAVE RS PRODUCTION RS Production 3 is a significant enabler for Orkla s operations in the Strategic Three Year Plan. RS Production not only strengthens the factory s capabilities for continuous improvements, RS Production also enables harmonized standards and knowledge sharing between all factories in Orkla. All installations are interconnected, thus there is one harmonized and aggregated platform for all factories performance. The purpose with this document is to guide you through the implementation of RS Production 3 in the group. Production Capabilities (Orkla Operations) coordinates the implementation and supports factory installations together with the suppliers (Good Solutions AB and Prevas AS). The document further describes what RS Production is and how it supports the factory. In addition to this document, there are additional tools and preparations for an installation such as a Survey prior factory visit, RSP3 online connection test system and a cost configurator of RSP3. One common system and platform for all factories Key topic in Performance Management for

3 CONTENTS ORKLA MANAGEMENT EXPECTATIONS INTRODUCTION ORGANIZING THE IMPLEMENTATION ORKLA PRODUCTION SYSTEM CASE STORIES: OFS TOLLARP AND OFN RÅBEKKEN ABOUT RS PRODUCTION TECHNICAL SETUP COST CONFIGURATOR WHAT IS IN THE ORKLA STD-PACKAGE? RS PRODUCTION EXTRA PARTS & PACKAGES TRAININGS AND SERVICES 5

4 INTRODUCTION ORGANIZING THE IMPLEMENTATION AUTUMN 2015, WHERE ARE WE? On June 30 th 2015, the frame agreement between Orkla, Good Solutions AB and Prevas AS was concluded. The agreement does not only give all factories of Orkla a significantly lower cost of installation. The agreement also gives all factories a great amount of functionality for catalyzing continuous improvements. In Orkla, 11 factories are currently using RS Production: - Orkla Foods Sverige (8) - Orkla Foods Norge (2) - Orkla House Care (1) Production Capabilities (Orkla Operations) has together with Good Solutions and Prevas defined joint processes related to coordinating the implementation of RS Production. These give all factories significant synergies in utilizing RS Production. The activities are further described on page 8. NEXT STEPS Below are the main next steps for implementing RS Production 3 through the frame agreement. The overall process is further illustrated on the next page. 1. Contact Niklas Myrbäck, Production Capabilities 2. Get in contact with Prevas AS and schedule visit or scoping project 3. Begin installation in 2016 or prepare budget latest in 2017 If you are uncertain about resources for implementation in 2016, a recommendation is at least to budget and plan for a pilot installation in There is also a possibility to implement a test installation (one measure point), this can be further explained by Prevas and Good Solutions upon the first meeting 6

5 OVERALL IMPLEMENTATION PROCESS ORGANIZING THE IMPLEMENTATION 1 2 Initiation Supplier contact Establish factory contacts Explain frame agreement & answer questions Prioritize high level plan to fit suppliers available resources PREPARING DEPLOYMENT Hand over factory contact to suppliers Supplier and/or factory mgmt. decide on visit or scoping 3 Factory visit ~0,5 day No cost for the factory Gives an indicative deployment offer (~80% accuracy) Scoping part of deployment instead of a separate activity 4 Factory scoping 1-2 days, cost depends on type of factory Costs are only attributable to activities that minimize the cost of the coming deployment Gives an accurate offer of the deployment FACTORY DEPLOYMENT (main steps, detailed plan set with Prevas) Installation Hardware, software and database servers Configuration Software setup aligned with central definitions & policies Training Standard delivery training Types of deployment Test installation Pilot installation Full installation Start-up Start-up and verification/han d over of installation Description of who owns the process in each step Orkla Operations Prevas AS Factory project management Continuous coordination and support from Production Capabilities See page 8 for more information 7

6 FIRST CONTACT WITH THE SUPPLIER PREVAS INFORMATION TO FACTORIES UPON FIRST CONTACT Initiation of RS Production (OEE) Projects - Your Options As you probably know, Orkla and Prevas have entered into a frame agreement with the intention to install RS Production, the highly acclaimed OEE solution from Prevas partner Good Solutions. Even though all terms and conditions for an installation project are regulated in the agreement, like software licensing, consultancy rates etc., the work needed prior to installation will vary a lot. This depends on the plants size and complexity, infrastructure, and ambitions for the OEEsystem. It s obviously important to know the cost of an installation project. As part of the Orkla/Prevas joint efforts to make implementation of RS Production in the plants as cost effective as possible, we have developed two alternative ways to get cost estimates, either a factory visit or a scoping project. Factory Visit A factory visit may be physical visit or a combined web meeting/phone call. Most of all, this will depend on the plant location. If it is outside the Scandinavian countries, we will most likely do it as a web meeting. If it is easy to go there, we prefer a visit. It will be done by a sales representative or a technician, and includes a presentation and demonstration of RS Production. Additionally is there a survey prior the meeting to understand the factory s needs, capabilities and limitations. This survey is based on a standard document template, which we expect you to have prepared before the visit. The factory visit is seen by Prevas as a sales effort, and will be done free of charge. Typically, it is done in less than half a day. The output is an indicative cost and a quotation of installing RS Production. Due to the factory visit s limited scope, the ambition is to give an indication with ~80% accuracy of total installation cost, based on standard components covered by the frame agreement. The cost indication will also point out other installation preparations that are not covered by Prevas. ORGANIZING THE IMPLEMENTATION ADDITIONAL TOOLS & PREPARATION This implementation guide Survey prior factory visit RSP3 online connection test system Cost configurator Contact your Prevas sales representative for more information of the above documents A factory visit should be sufficient for budgeting purposes. Scoping Project Sometimes a more accurate cost estimate is needed. In these cases a scoping project will be established. In situations where the factory is very large and its setup is very complex, it is recommended to establish a scoping project since a factory visit will be too rough and uncertain. The scoping project will be invoiced to the factory. In the scoping project, we typically spend one or two days, where we define all relevant aspects of an RS Production installation, including but not limited to user profiles, data inputs, presentation needs, stop codes, and infrastructure requirements. These activities will form the first phase of a deployment project, hence no efforts are in vain. The scoping project will be done by a senior consultant. The standard document template used in factory visits will be used as a tool for gathering information, and you are expected to have prepared this before the project starts. The output is a project plan, with manning, scheduling and our very best cost estimation of installing RS Production, including a formal quotation. 6 8

7 ORGANIZING THE IMPLEMENTATION HOW TO ORDER RS PRODUCTION AN ORDER OF RS PRODUCTION REQUIRES A CALL OFF FROM THE FRAME AGREEMENT THE CALL OFF TEMPLATE IS FOUND AS AN APPENDIX C IN THE FRAME AGREEMENT ORKLA FACTORY PREVAS AS GOOD SOLUTIONS AB ACCEPT OFFER ACCEPT CALL OFF VISIT AND/OR SCOPING PREPARE CALL OFF ORDER ORDER CONFIRMATION OK! ORDER CONFIRMATION Appendix C contains 3 pages, if there is an uncertainty of whether the specification in the call off is correct, consult Niklas Myrbäck, Production Capabilities 9

8 ORGANIZING THE IMPLEMENTATION CONTINUOUS COORDINATION & SUPPORT MAIN ACTIVITIES THAT ARE COORDINATED BY PRODUCTION CAPABILITIES. BELOW NOT COMPREHENSIVE, ADDITIONAL ACTIVITIES WILL BE PLANNED General coordination Harmonize performance Training & Best Practice IT infrastructure Track overall implementation plan and prioritize suppliers resources if needed Review, update and secure adherence to frame agreement Ad-hoc inquiries from factories Defining KPI calculations; e.g. loss categorization, OEE (Availability, Performance and Quality), Scrap, MTBF and MDT Establish policies that ensure equal configurations of the system over time (e.g. user profiles, reports, menus/interface) Arrange joint training through Webinars Develop training documentation and videos Secure expertise from Production Strategy & Development in RS Production Sharing best practice (e.g. through the Key User group) Install and maintain central servers (Orkla IT system owner of servers) Prepare IT resources prior factory installation Support and simplify installation work together with the suppliers, Orkla IT and Cognizant Development of RSP3 Gather development suggestions from factories Decide what should be considered joint development Examples of joint development : new languages, significant improvements and new modules affecting all factories (e.g. competence matrix) Incorporate system in other areas Integrate output data in SMART: Overall Supply Chain KPI:s Orkla Production System and Orkla Production Academy Kaizen network 1. The Key user group shall preferably contain representatives from all factories or, at least, companies. This group will be the main communicative channel for RS Production in Orkla. Currently this group does not have representatives from all companies. If you do not have a representative in the Key user group, please contact Niklas Myrbäck, Production Capabilities. 2. Status and progress of above will continuously be reported to the Key Users group 10

9 ORGANIZING THE IMPLEMENTATION MODEL FOR SHARING INVESTMENTS JOINT IT INFRASTRUCTURE & JOINT DEVELOPMENT GIVE SYNERGIES AND BUILD CAPABILITIES Distribution of costs is based on the number of factories and measure points installed per company CRITERIA FOR A DEVELOPMENT SUGGESTION TO QUALIFY AS JOINT DEVELOPMENT Each development suggestion is evaluated by Production Capabilities based on the four criteria Prevas/Good Solutions Central licenses and infrastructure Joint development Production Capabilities Benefits multiple factories Supports shared initiatives (e.g. OPS or Redesign) Installation Company Company Improves quality or catalyzes additional cost improvements Strengthens Operations capabilities Service & support Add-ons (e.g. ERP) Custom development Company Company Company Company Development suggestion are made through your factory s or company s Key User of RS Production or directly with Niklas Myrbäck, Production Capabilities Annual discount on service & support based on the number of installations made in Orkla 11

10 ORKLA PRODUCTION SYSTEM CONNECTION TO ORKLA PRODUCTION SYSTEM A MULTI-FACTORY IMPROVEMENT PROGRAM Orkla Production System (OPS) is: - A multi-factory improvement program - An aspirational view of good factory operations - A common framework to evaluate, discuss, and teach factory operations - Similar to Toyota Production System / lean manufacturing OPS is mainly about how we work and act, but a shop floor system like RSP3 is a powerful enabler for many of the OPS principles. DELIVER STANDARDIZED WORK CUSTOMER FOCUS SUSTAINABLE VALUE CREATION RESPECT FOR PEOPLE RIGHT FROM ME IMPROVE SIMPLE AND DIRECT RESPONSIBLE PEOPLE WINNING TEAMS BRAVE TRUSTWORTHY INSPIRING 12

11 SYSTEM ENABLERS FOR OPS ORKLA PRODUCTION SYSTEM EXAMPLES OF OPS PRINCIPLES WINNING TEAMS STANDARDIZED WORK Building high performing teams A clear standard for each activity Right team with clear communication and operational leadership Fact based precision culture Clear goals with plans and result tracking Adaptiveness to change Reflect on performance and improve Role descriptions Standardized operating procedures/ job instructions Order and cleanliness (5S) Autonomous maintenance checklists (Clean, Inspect, Lubricate) 13

12 RS PRODUCTION CASE STORIES OFS TOLLARP EXPERIENCED USERS OFS Tollarp has used RSP3 for a year and a half now, and the previous version RSP2 for several years before that. RSP3 is a necessity for performance management, says Erik Wendel, factory manager in OFS Tollarpsfabriken. We can really see the improvement this has given us over time. The production has become much more stable and predictable now, and we can have fact based discussions about where we can improve further. You cannot just set it up and forget it. Management must request the results from the system and ensure that basic data is kept up to date. We use the reports from RSP3 both in the morning meeting and in the weekly production meeting. There we ask both production and maintenance to report on the top three stop causes and the respective department s plans for corrective action to ensure that we have a shared improvement focus, says Erik Wendel. Production manager Mohammad Issa shares his experiences from the implementation process: There is some initial work to set it up. For us, finding the right trigger value for recording stops and requiring the operator to enter a stop code has been some trial and error. We started a bit short, and got too many registered stops the operator had to classify and comment. Then we raised the trigger value, focused on the biggest losses, solved them, and gradually reduced the trigger point again to work on the smaller stops. Setting up the hardware took a few days, entering the initial data took another couple of days. Training all the operators in using it also took some time, Issa recollects. Mohammad Issa demonstrating RSP3 to the Orkla Food Ingredients production network visiting Tollarp 14

13 RS PRODUCTION CASE STORIES OFN RÅBEKKEN PILOT INSTALLATION OFN Råbekken has had a pilot installation for about one year on three different production lines, and are now extending the system to several lines. Suad Kovacevic with RSP3 at the Picnic canning line Asle Andre Vagle, project leader, summarizes the experience: Overall, the implementation has been straightforward. It is mainly about connecting sensors and configuring options in the system. The support from Good Solutions has been very good. The things you need to get right are practicalities like correct placement of sensors and displays, ensuring that the displays have the right IP classification for the zone, and making sure the data collection cannot accidentally be turned off. It is a very good idea to visit another factory that has done this before to learn from them. We saw that a positive competitive spirit developed quickly between the different shifts and lines, says production leader Suad Kovacevic. People started sending text messages to each other with their production results, challenging them to do even better on the next shift. RSP3 has also made the operator s day much more predictable. We can see early in the day how we are doing and can estimate when we will be done for the day, or if any overtime will be needed. We have also had very good results in using the RSP3 data to identify and remove chronic sources of stops at the lines. Factories installing RSP3 should make sure that they find the right data sources and sensor positions to collect correct information, Kovacevic adds. People will lose interest and disregard the system if they see that the numbers are wrong or incomplete. It may be necessary to make some adjustments after initial startup to get this absolutely right 15

14 WELCOME TO RS PRODUCTION INTRODUCTION TO RS PRODUCTION FACTS FOR DAILY MANAGEMENT RS Production will save you the hours worked each day collecting, compiling and preparing for meetings. It will move your time from administration to value adding problem solving activities, actions and improvements. ANALYSIS AND TOOLS FOR IMPROVEMENTS RS Production is an easy to use analytical tool that helps you to find trends, patterns and deviations. It is a tool that helps you decide what actions to make to gain higher production efficiency and productivity. Beside RS Production are you also working with the known quality tools and root cause analysis. STANDARD OPERATION PROCEDURES When operators and production staff easily can access the right information at the right place at the right time you will reduces the number of errors caused by the human factor. RS Production has a range of features to support different types of documents and instructions in the operator environment. FASTER REACTIONS Access to real time visualizations and facts helps employees to take responsibility and make decisions regularly during the shift. RS Production will help your team to react and respond faster to disturbances and seal leakages as they happen. ERP/MRP REPORTING Todays ERP/MRP-systems lack good ways to gather facts about what really happens on the shop floor. RS-Production speeds up the reporting process and ensure that the ERP/MRP-system better describes what happens on the shop floor. 16

15 INTRODUCTION TO RS PRODUCTION Among other things, RS-Production has market's most user-friendly operator interface. It has given us many satisfied users and clients. RS-Production s Orkla STD-license includes many of the features that are costly additional functions in other systems (Analysis and Visualization for example). RS Production is a flexible and scalable system that can run in any modern IT environments. Real time production TV-screens Real time notices and information in Mobile application Automatic report print outs Production follow up Machine efficiency (OEE, TEEP, Availability) Downtime analysis Rejection analysis Cycle times Time axis Export data to Excel Dynamic analysis Trends Drill down Automatic machine logging with RS BlackBox or OPC Uptimes and downtimes Produced amounts Rejected amounts Automatic downtime coding Automatic changeover registration Cloud service in Orkla s Basefarm in Oslo 17

16 INTRODUCTION TO RS PRODUCTION USER FRIENDLY FOR OPERATORS MACHINE OPERATORS ARE OUR EXPERTS ON DISTURBANCES There are no others who have such a track of production disturbances as the operators and technicians who work in the production area. Therefore is RS-Production designed to be as simple as possible to them. It is true, as they say, "Shit in - shit out". If we can not offer operators the easiest to use tool it will weaker basis for daily management and improvements. RS Production has since the first version in 2007 remained at the front on the development of user interfaces for operators. PRODUCTION PLAN Run production orders or articles? Connect to ERP or import production orders from Excel? RS Production can even let you run without a production plan. DOWN TIME FOLLOW UP The easy to use stop coding is a vital part of RS-Production. Directly when the stop is registered it is shown to the operator. With only a few clicks on the touchscreen the stop is given a reason code and the operator have described what equipment that caused the stoppage. On the basis of a simple standard structure you will set up your own list of disturbance codes. 18

17 INTRODUCTION TO RS PRODUCTION REJECTION Operators register rejected produced amount on current previous production orders. Every rejection can be tagged with a reason code and describing text. MACHINE OPERATORS Operators easily logs in and out with magnet card, RFID or employee number. SHIFT REPORT Shift reports create good handovers and gives machine operators a full view of the performance on both their own shift and other shifts. 19

18 REAL TIME VISUALISATIONS INTRODUCTION TO RS PRODUCTION FASTEST WAY TO INCREASE EFFICIENCY AT HOME AND AWAY Everyone shares the same picture of output vs plan and current disturbances At the shop floor, in the office, away and at home Facts instead of rumors, guesses and feelings CLOSEST TO THE MACHINE AT THE OFFICE FACTORY SCREENS 20

19 AUTOMATIC REPORT PRINTS INTRODUCTION TO RS PRODUCTION YOU SHOULD USE YOUR CREATIVITY FOR IMPROVEMENTS Minimize time spent on preparation before meetings Increase the speed of improvement Facts instead of guesses and rumors It is common that too much time in daily life at the shop floor is spent to collect data and prepare reports and analyzes. With RS-Production, you always have fresh and secure information to the daily management and improvement meetings without spending time with papers and Excel. Your creative forces will instead be used to work on improvements. This creates increase in productivity and efficiency, both for you personally and for entire production. Data for reports and analyzes can be exported to Excel to be processed there or in any other tool. Trends Times and amounts OEE and disturbances Production follow up Times and amounts Shift reports Data tables Machine efficiency OEE, TEEP, Technical availability Data tables Downtime, rejects and reworks Pareto diagram Trends Visual distributions Data tables Maintenance Technical availability MTBF, MDT Capability Normal distributions Cp, Cpk Cycle times Average cycle times Longest and shortest cycle times Time axis 21

20 DYNAMIC ANALYSIS INTRODUCTION TO RS PRODUCTION TREND ANALYSIS AND DRILL DOWNS FIND PATTERNS AND TRENDS With the analysis tool you will find variations and disturbances that the human sense cant recognize. MACHINE EFFICIENCY Trend analysis and drilldown are keywords for the tool to help you find improvements to raise your efficiency and competiveness. CREATE FACTS A analyze tool is meant to set words and numbers to the feelings you may have. With proven facts you will have better chances to motivate activities and investments. TRENDS DOWNTIME CYCLE TIMES CAPABILITY 22

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22 TECHNICAL SETUP TECHNICAL SETUP YOUR SERVER IS ALREADY PREPARED AT BASEFARM To make technical setup and installation as easy as possible there are already servers prepared for you at Orkla Basefarm. TEST YOUR CONNECTION TO THE SERVER A test environment is set up with a typical database with many years of production data in it. Try your connection to the RS Production servers at Basefarm by connecting to it. You connection time and download times will be registered automatically. Instructions are available at Yammer. RUNS ON ALL TYPES OF PC-STATIONS Desktop station, laptops and thin clients. HARDWARE ON SHOP FLOOR LEVEL RS Production is at the shop floor normally run on touch screens. The idea with touch screens is to make the user interface as easy to use as possible and easily available for machine operators. Depending on the environment in your production (moisture, dust etc.) you can either use the standard Panel-PC with IP64 classed front or the IP65-classed Panel-PC. In case you are interested in a setup where you run RS Productions operator environment on standard PCstations or thin clients you need to discuss details with a sales representative. 24

23 TECHNICAL SETUP H PANEL-PC WITH WIN7 (IP64 FRONT) Standard touch screen for machine operators user interface. Also working as a machine signal logger when connected to the RS BlackBox. Delivered ready to use with all components installed. Suitable for dry areas. IP64 indicates the dust and moisture resistance. H PANEL-PC WITH WIN7 (IP65 ALL OVER) Standard touch screen for machine operators user interface. Also working as a machine signal logger when connected to the RS BlackBox. Delivered ready to use with all components installed. Suitable for wet areas. IP65 indicates the dust and moisture resistance. RS BLACKBOX RS Production standard hardware to collect machine signals from production. Collects 24V-signals or connects to a Profibus network. Connects to the server via Ethernet (LAN/WLAN) or to Panel-PC in production via RS-232 COM. RS BlackBox has no IP rating. It operates in the 0 to 55 degrees Celsius and 10% to 90% humidity. OPC OPC is another common standard way to collect data from machine equipment. 25

24 WHAT WILL THE COST BE? COST CONFIGURATOR USE THE EXCEL COST CONFIGURATOR Get rough figures for your cost budget by using the Cost Configurator in Excel. All you need to do is estimating the number of licenses, hardware and services you will need. It is available at Yammer 26

25 MEASURE POINTS COST CONFIGURATOR HOW MANY LICENSES DO WE NEED? The Measure point is a very central concept and unit in RS Production. In many types of production, one Measure point is equal to one machine. Measure point In more complex flows you will have one or more Measure Points per production line or flow. Please refer to the coming configuration instructions with best practices for how to identify Measure points. Typically a Measure point in your production flow where you Can count times and amounts Can report disturbances (reasons, stations, text comments) Can follow up efficiency (OEE) and other Performance Indicators Can have a production plan Can log in/out machine operators 27

26 WHAT S IN THE ORKLA STD PACKAGE? RS PRODUCTION ORKLA STD-LICENSE K200 A GREAT SET OF IMPROVEMENT TOOLS RS Production Elemental Orkla Standard license is delivered with the following of RS Production s Extra Parts & Packages. Note that additional configuration and training is recommended for all included Parts & Packages. Configuration is for example the specific setup to fit the production site. P100 PK PK201 PK202 PACKAGES INCLUDED PK200 Standard Operation Procedures PK201 Change Over Reduction PK202 Maintenance Support PK203 Stable Processes PK205 Line/Flow/Cell Extension PK207 Central Management PT210 Alarm Escalation (Automatic) PT221 Automatic Competence Matrix PT223 Extended Disturbance Follow up (coding of speed losses) PT224 Andon (Manual call to support resources) GEAR UP - STEP BY STEP Orkla s RS Production STD-license has a library of modules (RS Production Packages) designed to support different improvement activities. RS Production s flexibility allows you to gear up step by step and grow at your own pace. You decide your own steps based on your needs. 28

27 RS PRODUCTION ORKLA STD-LICENSE PK200 STANDARD OPERATION PROCEDURES PK200 - Standardized work creates opportunities to harmonize approaches and spreading best practice. This is done by linking instructions and checklists to RS Production Measuring points and articles. Standard Operations provides access to RS Production s tool to create and edit documents. The tool is similar to Microsoft Word in the sense that you can write and format text, add images and make complete instructions. K200 P100 PK PK201 PK202 Both PDF files and documents from the RS Production document tools can be linked to menu buttons in Operator Tools. Standard Operation Procedures also include Info Flash a tool for instructions time limited and targeted instructions. Instructions are shown to operators automatically as they change the running article. Example of showing a webpage inside Operator Tools Example of an automatically generated checklist 29

28 RS PRODUCTION ORKLA STD-LICENSE PK201 CHANGE OVER REDUCTION COUNTDOWN TO CHANGE OVER A real time image in Office Tools that also can be displayed on a TV screen. Displays booth target and remaining time for changeovers, which leads to better preparations for preparatory machine adjustments. K200 P100 PK201 PK202 CHANGE OVER REPORT A page in Office Tools, reporting and analysis tool that shows which combinations of shifts and articles that provides the longest changeover times. By highlighting the changeover time, you can see what to focus on and what actions to be taken to make the greatest time savings. PK CHANGE OVER TABLE A table in Office Tools, reporting and analyzis tool that displays a row for each shift. The table can be sorted and filtered at measuring point, the previous article, new article, operator, measured Setup Time and comments. CHANGE OVER TIME VISUALIZATION A page in Operator Tools showing: The measuring point last changeover times The operators recent changeover times on the point of measurement (requires operator login) The article last change over times on the point of measurement Text comments in the last change over stops. Example of change over times shown in Operator Tools. 30

29 PK202 MAINTENANCE SUPPORT Maintenance Support is a great tool to spread ownership and responsibility to work with increased technical availability within the organization. Operator Tools Checklists for control points and operator maintenance Office Tools Reports for MTBF and MDT (PT205) Office Tools Report of Technical and Availability Office Tools Maintenance Report RS PRODUCTION STD-LICENSE K200 PK201 P100 PK PK202 CHECKLISTS FOR CONTROL POINTS AND OPERATORS MAINTENANCE Establish standards for the controls and machine-oriented service performed. Ownership and responsibility is often be delegated to the operators and technicians. Often this means that it is an administrative task to make checklists on paper for operators and technicians. By moving the checklists into the system, will the daily work be much more efficient and provide for more need-based lists, which will save much time on administration and compilation. MAINTENANCE REPORT WITH MTBF AND MDT Provides a comprehensive overview of trends and to visually identify the machines that deviates. It also shows the input times that the calculations are based on to increase the understanding. REPORT FOR TECHNICAL AVAILABILITY Provides a comprehensive overview of trends and to visually identify technical availability. It also shows the input times that the calculations are based on to increase the understanding. Example of MTBF and MDT Trends in Office Tools 31

30 RS PRODUCTION ORKLA STD-LICENSE PK203 STABLE PROCESSES Stable Processes is a tool to move the ownership and responsibility for the continuous proactive quality assurance to the operator level. Process Stability refers to the consistency of the process. If the process behaves consistently over time, then we say that the process is stable or in control. Statistical Process Control, SPC is a method of quality control which uses statistical methods. SPC is applied in order to monitor and control a process. Monitoring and controlling the process ensures that it operates at its full potential. K200 P100 PK PK201 PK202 In all types of processes variations occur. In a manufacturing process, it may mean, for example varying temperature and humidity or poorly calibrated measuring instruments. This variation is the source of poor quality and must therefore be identified, monitored and possibly be reduced. Real time process trend and capability in Operator Tools Operator Tools Form for reporting measurement and process values Operator Tools Real-time display of data series, trends and capability Real-time alarms based on trends that leads to coming quality failures Office Tools Reporting Tools to follow up on capability Office Tools Export to excel Example of capability visualisation in Office Tools 32

31 RS PRODUCTION ORKLA STD-LICENSE PK205 LINE/FLOW/CELL EXTENSION Extra functions necessary when you use RS-Production in a flow. Equipment follow up Scrap difference calculation K200 P100 PK201 PK202 Master Measure Point PK EQUIPMENT FOLLOW UP RS Production offers the possibility to let operators both give a reason code and also tell what equipment on the line that stopped. This helps you keep a clean and simple tree of reason codes and combine it will local equipment. This is a must have if you want to have centrally defined stop reason codes and still want to let the local sites add their equipment codes. SCRAP DIFFERENCE CALCULATION Let you calculate waste for a Measure Point as the difference between amounts on two different Measure points. MASTER MEASURE POINT Let you change article or production order on several slave Measure Points automatically when you change on the Master Measure Point. 33

32 RS PRODUCTION ORKLA STD-LICENSE PK207 CENTRAL MANAGEMENT All tools you need to on the local site to enable central aggregation. PT210 ALARM ESCALATION (AUTOMATIC) Tools to send alerts to support resources and management. Reacts automatically on different disturbances on different time thresholds. Send messages to different people depending on what work shift it is and what Measure Point it is. K200 P100 PK PK201 PK202 Sends predefined messages to predefined recipients via SMS and . PT224 ANDON (MANUAL CALL TO SUPPORT RESOURCES) Manual call buttons in Operator Tools to call different resources. Send messages to different people depending on what work shift it is and what Measure Point it is. Sends predefined messages to predefined recipients via SMS and . 34

33 RS PRODUCTION ORKLA STD-LICENSE PT221 AUTOMATIC COMPETENCE MATRIX A Competence Matrix is a tool to create and visualize a group's collective expertise and your training needs. Competence Matrix can be used both in the daily labor planning and the planning of trainings. VISUALIZE YOUR SKILLS With the Competence matrix, you always have easy access to see what the competences that are in place at the factory right now. K200 P100 PK PK201 PK202 Competency areas are linked to RS Production s Measurement points. Using Operator logging in Operator Tools provides you with an easy to use way to quickly track what competences that are in place to deal with a situation that arises. VISUALIZE YOUR TRAINING NEEDS With the competence matrix, you always have easy access to how much competence you have compared to the competence you need to meet your commitments to your customers. A clear overview shows you in which areas you need higher competence levels. Example of competence matrix showing competence areas as columns and people as rows. 35

34 EXTRA PARTS & PACKAGES MORE TOOLS FOR IMPROVEMENTS EXTRA PARTS & PACKAGES K200 PK201 This chapter presents some further Parts & Packages available for RS Production outside the Orkla STD-license. PRODUCTION SITE LEVEL P100 PK202 PS102 RS Production Integration Server (including an ERP integration project) MACHINE LEVEL PT201 PK PK204 Track and Trace PK208 Development Studio PS102 PK209 Planning Tool PT201 Mobile PT218 OPC Client PT222 Post calculation P208 Customer (Site) unique page/layout P309 New Language P310 Free Unit Counters 36

35 EXTRA PARTS & PACKAGES PS102 INTEGRATION SERVER Includes both the RS Production Data Model Server and the RS Production Integration Server. The Data Model Server enables a RS Production Developer to modify and extend the local data model to suite unique demands. The Integration Server opens up the RS Production Web Service API for external software. It also enables RS Production Developers to import and export data to and from other data sources. The Integration Server comes together with an ERP-integration project using PINT205 to a fixed price (see prices Appendix B). About PINT205: PINT205 ERP-INTEGRATION WITH PRODUCTION PLAN, PARTIAL REPORT, AND FINAL REPORT PINT205 is delivered together with PS102 RS Production Integration Server. A standard two-way integration of order management to any ERP-system. The solution is based on a standardized middle layer storage on a SQL/XML server. RS Production reads and writes on this model layer according to the detailed specification. 37

36 EXTRA PARTS & PACKAGES PK204 TRACK AND TRACE Collects id from a specified list of ingoing materials. Lists are set up on article level. Can also create a unique number series of batch numbers for produced units. Basic tools in Office Tools are included to track and trace. PK208 DEVELOPMENT STUDIO The tool the Good Solutions and development and delivery partners uses to build and maintain customer unique report pages. Developer Training Basic is mandatory. Earlier developer experience is highly recommended. PK209 PLANNING TOOL Rule based manual fine planning tool that amongst others takes use of RS Production s real time machine data to visualize off set to plan. PT222 POST CALCULATION Helps you find deviations between assigned set up times, cycle times and each times. PK209 Planning Tool 38

37 EXTRA PARTS & PACKAGES PT201 MOBILE APPLICATION App giving push notices and updated information on ongoing production and deviations. Each user sets their own filter to limit the message traffic. You can send questions and text comments on events like orders, shift changes and deviations to all users including machine operators. Runs on both ios and Android. PT218 OPC CLIENT Additional Part that opens up RS Production as an OPC Client that can read/write from/to OPC-servers and capture much larger amounts of data compared to what you can do with RS BlackBox. P308 CUSTOMER UNIQUE PAGE/LAYOUT Allowing your site to use developer services to build your own report- and analysis pages and TV-screens. 39

38 TRAININGS AND SERVICES TRAININGS AND SERVICES WE WILL HELP YOU TO GET STARTED A successful RS Production start up includes both technical aspects and a great deal of change management. Going into digitalized production follow means new possibilities for several of the daily processes. By using skilled and experienced delivery consultants and joining the trainings you can make sure to gain the most possible from your new tool for production visualization. USER TRAININGS The user training focuses on the foundations in RS Productions for OEE and disturbance follow up. The target is raise the ability to configure and manage RS Production in a way that it maximizes your chances to support your daily management processes and improvements with facts. TRAININGS FOR ORKLA STD-PACKAGES Most of the packages in the Orkla STD-license requires additional training to get started. There are training packages prepared ask your sales representative for more details for each package. 40

39 TRAININGS AND SERVICES STANDARD DELIVERY START UP (1 2 MEASURE POINTS) A minimal 3 day standard project for starting up OEE measurements in a pilot environment. With the help of initial training and checklists you will do a large part of the configuration work by yourself. Larger installations and help to configure and start up Orkla STD-packages will be offered. WE ARE LOOKING FORWARD TO HELP YOU! 41

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