Increased productivity and process visibility at Pioneer Foods

Size: px

Start display at page:

Download "Increased productivity and process visibility at Pioneer Foods"

Lisa Higgins
6 years ago
Views:

real-time information and is value for money, I didn t have to look any further than the Equipment Effectiveness Suite from Software Toolbox.

1 [ Success Story ] Pioneer Foods Ltd. Industry: Food and Beverage I was looking for an equipment performance monitoring product for my clients that works, is easy to configure, fast to roll out, has an open integration platform, delivers real-time information and is value for money, I didn t have to look any further than the Equipment Effectiveness Suite from Software Toolbox. - Gordon Schoombie, perations Director, Systems Anywhere Goals Real-time data collection, analysis and reporting The ability to do Root Cause Analysis pen and easy integration with other solutions Easy configuration and customisation to cope with change Provide web access Solutions and Products Equipment Effectiveness Suite Top Server Challenges To implement an EE system as a management tool to uniformly manage efficiencies and waste on production lines across production facilities across the country on a tight budget and in less than five months Results Reliable trustworthy information Real-time performance and yield information at any line or plant can be checked from anywhere and at any time (web interface) Increased productivity Increased productive time Improved efficiency Less downtime and better downtime analysis Faster decision making Improved operator interaction and contribution Drill down capability and Root Cause Analysis

2 About verall Equipment Effectiveness EE is a hierarchy of measurements developed by Seiichi Nakajima in the 90s to evaluate how effectively a manufacturing operation is utilised. It is based on the Harrington Emerson way of thinking regarding labour efficiency. A B C D E Net operating time Running time Target output Actual output Actual output TTAL PERATING TIME Availability = B/A Speed Performance = D/C Downtime Not scheduled Background production facilities throughout South Africa Having identified the need for more effective management of their equipment assets, Pioneer Foods commissioned system integrator Systems Anywhere to implement an online EE solution that would be rolled out on lines at production facilities across South Africa. The result is business and operational benefits through real-time decision-making. Goals and Requirements The goal of this project was clear but somewhat daunting, says Gordon Schoombie, perations Director at system integrator Systems Anywhere Coastal. It was to implement an EE system as a management tool to uniformly manage efficiencies and waste on production lines across production facilities across the country on a tight budget and in no longer than five months. It sounds overwhelming and after you ve had the chance to think about it, it gets a lot worse. F Good output Defect Quality = F/E EE = Availability X Performance X Quality X 00 Determining verall Equipment Effectiveness. Example: (0.)*(.)*(.9)*00=9% EE. World-standard EE stands at % which is the result of 90% Availability, 9% Performance and 99% Quality. In addition to their having access to expert and readily-available technical support, Pioneer Foods specified that the system must be capable of: Real-time data collection, analysis and reporting so as to be a management system as well as an information system for its users. Drill down capability and the ability to do Root Cause Analysis as well as rolled-up information and management dashboards pen and easy integration with other solutions Easy configuration and customisation to cope with change Web access Lastly, the solution supplier must provide change management protocols and get the buy-in of operators for the new system. The solutions we needed for this project would have to be tried and tested, fast and easy to implement as well as low cost if we were to comply with Pioneer Foods requirements, says Schoombie. With the help of Wonderware Southern Africa, we contacted Software Toolbox who recommended their Equipment Effectiveness Suite (EES) as well as TP Server for PC and I/ management the latter is a reliable standard with all our installations. Visualisation of information would be done with Microsoft.NET as an HMI route would have exceeded the budget and data collection using Beckhoff PLCs as connecting to existing PLCs was out of the question.

WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE

INPUT 0 9 0 9 0 9 0 Tank Tank Tank High (more than 00mm) Reactor DC INPUT 0 9 0 9 0 9 0 F F F F F F F F F9 F0 F F F F F F DC

Pioneer Foods had already evaluated two other systems with pilot implementations.

While we were competitively priced, the richer functionality we were offering and the proof of its ease of implementation

ur final choice of Systems Anywhere was based on the company s successful track record of a creative and innovative approach

We also agreed on their selection of reputable Software Toolbox solutions supported locally by Wonderware Southern Africa,

VPN External users EE overhead displays Router firewall EES Server TP Server Primary Core Switch EES operator station

Seiichi Nakajima in the 90s to evaluate how effectively a QUALITY Allen-Bradley PanelView 000 manufacturing operation is

System Topology As per Infrastructure It became quickly obvious that one of the benefits of this project would be to ensure

3 WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE WS-X0-0GB ATUS 0 GIGABIT ETHERNET MDULE QUALITY Allen-Bradley PWER RUN BAT Logix0 RUN REM I/ Rs PRG Tank High Pressure P Temperature T Level L Pressure P Reactor DC INPUT Tank Tank Tank High (more than 00mm) Reactor DC INPUT F F F F F F F F F9 F0 F F F F F F DC UTPUT Success Story > Pioneer Foods Ltd. Pioneer Foods had already evaluated two other systems with pilot implementations. When it was our turn, we implemented a working pilot within four days, says Schoombie. This included hardware installation. While we were competitively priced, the richer functionality we were offering and the proof of its ease of implementation must have appealed to Pioneer Foods sense of future-proofing and independence. ur final choice of Systems Anywhere was based on the company s successful track record of a creative and innovative approach to projects. We also agreed on their selection of reputable Software Toolbox solutions supported locally by Wonderware Southern Africa, says Piet Burger, Supply Chain Executive, Pioneer foods. VPN External users EE overhead displays Router firewall EES Server TP Server Primary Core Switch EES operator station Catalyst 00 SERIES Local users Multi-layer switch VLAN 0 Implementation EE is a hierarchy of measurements developed by Seiichi Nakajima in the 90s to evaluate how effectively a QUALITY Allen-Bradley PanelView 000 manufacturing operation is utilised. It is based on the Harrington Emerson way of thinking regarding labour efficiency. System Topology As per Infrastructure It became quickly obvious that one of the benefits of this project would be to ensure that everyone was on the same page regarding the measurement of EE, which was being done differently at each plant that we visited, says Schoombie. The determination of EE is a universal standard and not subject to individual interpretation. It s also not an excuse to measure the effectiveness of people so that someone can be blamed for poor results. This by itself required the implementation of an extensive change management programme for which we enlisted the help of Competitive Dynamics International. SWITCH VLAN VLAN 0

ne of the ESS dashboards showing EE time as well as availability, performance and quality At our Worcester bakery, EES has assisted us in identifying the production bottlenecks and by launching a

4 ne of the ESS dashboards showing EE time as well as availability, performance and quality At our Worcester bakery, EES has assisted us in identifying the production bottlenecks and by launching a focused improvement project we managed to increase our production capacity by %. - Jabbaar Mookadam, Divisional Technical Manager, Essential Foods: Bakeries. - The project was started in May 0 and commissioning was completed within the specified time period by the end of September of that year. The system was integrated with Pioneer Foods intranet and provides Internet access through which full remote support, configuration and control is possible. Web access also provides users drill-down reporting and dashboard capability while scheduled reports are ed to relevant personnel. The EE analysis dashboard has been kept as simple as possible and lists the equipment as well as the reason for its downtime such as product change or stoppage due to failure or some other cause, says Schoombie. ne of the features of EES and something not usually seen in other solutions of this type is the ability to split downtimes between production and maintenance. Downtime causes can be either entered manually or scanned from barcodes. Insofar as reports are concerned, we used those supplied in EES and we kept them clear, concise and easy to analyse. Since implementing EES at our breakfast cereals plant, I am now able to remotely monitor line performance and provide guidance in order to improve line efficiencies, reduce waste and illustrate the impact of changeovers. The data is available immediately and reports are easy to draw and interpret, says Jacques Weidemann, Unit Manager Atlantis Cereals, Groceries Systems Anywhere monitors all lines at sites on a / basis. Load shedding, EE values below par or other alarms are instantly visible on a country map so that appropriate and timely action can be taken.

5 Business Benefits Reliable trustworthy information verified against manually-derived figures and key to gaining operator confidence Real-time performance and yield information at any line or plant can be checked from anywhere and at any time (web interface) Increased productivity Increased productive time because of improved EE, more machine time is available for production which meant not only increased efficiency but increased throughput as well perational Benefits Improved efficiency Less downtime and better downtime analysis instant alert of line downtimes and their reasons allows maintenance personnel to act quickly and to address the right problem Faster decision making Improved operator interaction and contribution Drill down capability and Root Cause Analysis also quick determination of what equipment is responsible for availability Conclusion Even including the tight budget and time constraints, the project has met all of Pioneer Foods, goals and criteria: We finished within budget and two days ahead of schedule, says Schoombie. This EE implementation also provided some unforeseen benefits such as a common reality on EE and the empowerment of operators to optimise their processes and contribution through real-time knowledge and instant feedback on the effects of their actions. We ve had a very positive experience with regards to the installation, ease of use and training. Support is efficient and issues/queries are resolved on the fly. - Jabus Wessels, Manufacturing Executive, Essential Foods: Grains Wonderware Southern Africa Block E, EH Business Park sborne Lane Bedfordview South Africa REL: 0/ 0 Wonderware Southern Africa. All rights reserved. Wonderware is a trademark of Schneider Electric SE, its subsidiaries or affiliates. All other brands and product names may be trademarks or servicemarks of their respective owners

Enhanced remote monitoring of Africa s only nuclear power station helps Eskom engineers

Enhanced remote monitoring of Africa s only nuclear power station helps Eskom engineers [ Success Story ] Eskom Industry: Utilities We experienced the benefit of the plant status system you pioneered. When the unit tripped, I got my e-mail, plant views, SMS and could respond very timeously