GEN-INT-13 B Quality KPIs on the Shop Floor

Transcription

1 GEN-INT-13 B Quality KPIs on the Shop Floor Eddie Cruz, Johnson & Johnson Chris Monchinski, Automated Control Concepts 13 October Automated Control Concepts, Inc. 1

2 Today s Agenda Introductions Project Objectives Implementation Results 13 October Automated Control Concepts, Inc. 2

3 Today s Agenda Introductions Project Objectives Implementation Results 13 October Automated Control Concepts, Inc. 3

4 Introductions Eddie Cruz Manager of Engineering at Lititz, PA Facility 20 Years at Johnson & Johnson Successful Implementations in Batch, MES, SPC Chris Monchinski Leads Manufacturing IT Group for Integration, Project Management 20 Years at Automated Control Concepts, Inc. Current Co-Chair of ISA 95 Committee Working together for 15 years. 13 October Automated Control Concepts, Inc. 4

5 Today s Agenda Introductions Project Objectives Implementation Results 13 October Automated Control Concepts, Inc. 5

6 Johnson & Johnson Zero Defect J&J Embarks on Global Zero Defect Initiative Provide on-line SPC analysis for pre-defined CTQ values which will result in better process understanding and eventually lead to process improvement projects 13 October Automated Control Concepts, Inc. 6

7 Johnson & Johnson ACC selected as vendor for deployment of On Line SPC Tool in support of Zero Defect for North America Lititz Pennsylvania Los Angeles California Selection of Wonderware QI Analyst Complements existing install of Wonderware at North American facilities North America began rollout in 2012

8 Johnson & Johnson Asia Pacific Rollout 10/1/2011 Vendors Selected for North America 2/1/2012 Pilot Lines for Lititz, PA Phase 1 Rollout, Lititz, PA 5/1/2012 5/1/2013 Phase 2 Rollout, Lititz, PA 9/1/ Pilot Lines for Los Angeles, CA 9/1/2012 Today Phase I Rollout 9/1/2012-5/1/2013 Phase II Rollout 9/1/2014-1/16/2015

9 Johnson & Johnson Lititz Project Description: To implement SPC and assess process robustness, recommend and implement improvements for selected lines and manufacturing platforms. Scope: Lines in , 2007, 312, 336, 2002, 2001 and 2003 Lines in 2013/ , 2005, 2006, 309, 337, and 315 Process parameters (where available) Fill Weight, torques, integrity checks, rejects Defect/Reject Information 9

10 Johnson & Johnson Lititz Goals Real-time Cpk values for critical to quality parameters per line. Establish simple to understand ranges, scorecard Train Personnel to Understand and React to Critical to Quality Issues. Real-Time Operator friendly statistical charts (look for measurable terms Waste/defect reduction goals Cost savings Personnel Improvement, Job satisfaction, Empowerment Safety/Ergonomics related to handling of tubes/bottles improvements 10

11 Today s Agenda Introductions Project Objectives Implementation Results 13 October Automated Control Concepts, Inc. 11

12 Solution details Wonderware QI Analyst Chosen Complement, Extend Investment in Wonderware Easy to Integrate, Extend Integrated into ArchestrA Variable CtQ s (Fill Weight, Cap Torque) Attributes (10-15 rejects/defects per line) Automatic Checkweigher, Seal Testers 12 Lines at Lititz, PA Site 18 Lines at Neutrogena, Los Angeles, CA Site 13 October Automated Control Concepts, Inc. 12

13 System Architecture - Lititz WCONUSLZDVQIS (Dev/Test. Instance) QI App Server QI Database CONUSLZWWGR Galaxy Lititz (Existing) CONUSLZAPP01 Report Server SQL Server, SSRS (Existing) LTZAMRAPP20 CheckWeigh DB server (Existing) Listerine Line 2007 HMI WW InTouch SCADA QIA Workstation Listerine Line 2001 HMI WW InTouch SCADA QIA Workstation Listerine Line 2002 HMI WW InTouch SCADA QIA Workstation Listerine Line 2003 HMI WW InTouch SCADA QIA Workstation WCONUSLZQISSQL (Prod Instance) QI App Server QI Database CONUSLZAOS2 Object Server AOS Archestra (Existing) CONUSLZHIST1 Wonderware Historian Server (Existing) Bengay/Desitin Line 303 HMI WW InTouch SCADA QIA Workstation Lubriderm Line 312 HMI WW InTouch SCADA QIA Workstation Neosporin Line 336 HMI WW InTouch SCADA QIA Workstation Line 2001 Data Concentrator Line 2002 Data Concentrator Line 2003 Data Concentrator Line 303 Data Concentrator Line 2007 Data Concentrator Line 312 Data Concentrator Line 336 Data Concentrator Line 303 OCS Check Weigher 13

14 Fill Weight Existing Data Collection Process QIA Integrated to existing SQL Database (External Samples) Synchronize Product Lists, Specifications Allow us to leverage existing, validated process and get early payback. Little disruption to the operator. 13 October Automated Control Concepts, Inc. 14

15 Existing Data Integration QIA Analyst Data Entry CheckWeigh DB Transfer Process (Timed or Triggered) QIA Process DB QI Analyst Transfer Process (Timed or Triggered) Check Weigh DB Data Entry Line Terminal 15

16 Real Time Chart XBAR-R 13 October Automated Control Concepts, Inc. 16

17 Historical Chart XBAR-R

18 Fill Stem Analysis Break weigh samples down by individual fill stems Identify trends and issues with machine Strive for consistency in the filler operation Use QIA Note field to capture the context of stem number for each variable weigh sample 13 October Automated Control Concepts, Inc. 18

19 Real Time Chart I-MR

20 Automatic Check Weigher Integration to Check weigher Samples collected via OPC through Archestra, Historian QIA pulls data from Historian Every 10 th fill weight collected 13 October Automated Control Concepts, Inc. 20

21 Automatic Check Weigher QIA Analyst Historian Connector QIA Link to InSQL Process Equipment Driver InSQL Datastore QI Analyst Wonderware Historian MDAS to Historian InSQL Datastore FS Gateway Wonderware System Platform Data Collection (Ethernet / OPC) Data Collection (Ethernet) Data Collection (Serial/DIO) 21

22 Automatic I-MR

23 Defect Analysis Defect Counters in Local Machine PLCs Leverage Data Concentrator PLC to aggregate defects Totalize Defects by Machine Center for every 1000 units counted. Collect data in Historian QIA collects data from Historian based on update from PLC KPIs (Cpk, DPMO, Yield) 13 October Automated Control Concepts, Inc. 23

24 Rejects Assessment - Lititz Line 312 Inspection/Reject Systems Assessment: Machine Center Defect Name Inspection System Data Accessibility Reject Status Notes/Comments Filler/Capper Pump Placer Labeler Does not show if rejected for high or Low/High Fill Filler Load Cell In DAPA but with no Scrap low granularity - shows as Missing Cap photo eye sensor "line reject" Scrap High Cap photo eye sensor Scrap/rework* *6oz high caps are reworked Missing Straw High Cap (pump) Missing Cap (pump) Missing Pump (orientation) Front Label Spec Number Back Label Spec Number Back Label Lot Code Back Label Exp Date* photo eye sensor Vision System - Cognex Vision System - Cognex Vision System - Cognex Vision System - Systech Vision System- Systech Vision System- Systech Bundler Missing bottle photo eye sensor Case Packer/Printer A-B PLC can be accessed via Data Concentrator Not in DAPA (considered "reworkable") Scrap Scrap Scrap Scrap Rework Rework Rework Must be scraped These rejects could be reworked but currently assumed scrap due to potential for missing straw (same reject lane) Includes: wrong code, misread, no code, incomplete code Vision System- Systech Rework *Some skus have no exp. date Need to provide discreet output for reason code Rework Shuts down line (no rejection) Open Flap Detection photo eye sensor Rework Shuts down line (no rejection) Barcode Reader laser scanner A-B PLC can be accessed via Data Rework Rejected at Case inspection system Concentrator Case Count Verification PECO Rework Rejected at Case inspection system Palletizer Pallet Tag Barcode Bar Code Scanner A-B PLC can be accessed via Data Concentrator Rework Pallet is is held from proceeding to pickup station 24

25 Defect Analysis QIA Analyst Historian Connector QIA Link to InSQL Process Equipment Equipment Equipment Data Concentrator PLC DAS Server AOS System Platform InSQL Datastore QI Analyst Wonderware Historian MDAS to Historian InSQL Datastore Wonderware System Platform Data Collection (Ethernet / OPC) 25

26 Results Defects Pareto 13 October Automated Control Concepts, Inc. 26

27 Results P Chart 27

28 Defect Analysis - KPIs 28

29 Alarming Interface between QIA and ArchestrA Alarms evaluated and logged in QIA Transferred to ArchestrA via object script Become ArchestrA alarms, can be logged, seen across the network. 13 October Automated Control Concepts, Inc. 29

30 CpK/Ppk Scorecard 13 October Automated Control Concepts, Inc. 30

31 Web Reporting

32 Web Reporting

33 Today s Agenda Introductions Project Objectives Implementation Results 13 October Automated Control Concepts, Inc. 33

34 Results Fill Weight Variance Tighter controls, tolerances result in reductions in costs on materials, rework. Defect Analysis Driving better process understanding and process improvement projects. OEE improvements resulting Adherence to Corporate Reporting on Cpks 13 October Automated Control Concepts, Inc. 34

35 Who are we? Established:1983 Wonderware Solution Provider Mission: Provide high quality control and information solutions, products, and services to manufacturing and utility companies Strategically deploy new technology & implement proven technology Core Values: Long-term relationships Culture of customer satisfaction High Level of Ethics, Integrity & Excellence Stability 13 October Automated Control Concepts, Inc. 35

36 What s Next? 13 October Automated Control Concepts, Inc. 36