Why OEE as a Metric? Learn how to design a system to maximize the visibility into OEE

Transcription

1 Why OEE as a Metric? Learn how to design a system to maximize the visibility into OEE v3

2 Today s Topics The Value of OEE Use OEE to Maximize Visibility System Design Meeting Typical Customer Outcomes

3 Christopher Carlins Senior Application Engineer Eight Years Manufacturing Solutions 1 st Class Customer Support 7 Senior Application Engineers Industry Experience 150+ years 1 st Class Education GE STEP Certified Scheduled and On-Site Custom Classes 1 st Class Customer Service Design, Pilots, Assessments Product Selection and guidance IndustrialAutomationNation.com

4 GE Manufacturing Software Installations Katie Moore - GE Global Industry Manager - Manufacturing Many of those customers start with OEE

5 The Value of OEE Overall Equipment Effectiveness

6 OEE has Proven, Measurable Results GE's Proficy OEE software helps manufacturers to optimize their production efficiencies and target improvements to support Operational Excellence 39% 35% 5% Reduction in Downtime Plant improvement in OEE Increase in production yields

7 OEE Adds Real Value by deploying Proficy OEE, manufacturing organizations worldwide are supporting their strategic goals and outcomes Increase in available runtime Reduction of scrap and waste Increase profit Improved Production Output

8 Use OEE to Maximize Visibility How to design a system to drill in to OEE

9 Good Produced vs. Ideal Produced Yesterday s Morning Shift Shift is parts per minute Last Week s Production Two (2) Shifts per day * Five (5) days Ideal Produced : 48,000 parts Ideal Produced : 480,000 parts First-pass Good Produced : Shift OEE is : 50 % 24,000 parts First-pass Good Produced : Weekly OEE is : 49 % 235,200 parts Weekly Avg OEE 1 year ago: 45 %

10 OEE is a Health Monitor It tells you when something is wrong Or when something is going well Oh, I see! Today OEE is LOW but why? Add detail to find out why the process is suffering.

11 How to Calculate OEE GOOD UNKNOWN W S DT OEE = Total GOOD vs. Scheduled SCHEDULED DT Availability = Operational vs. Scheduled S Performance = Produced vs. Operational W Quality = Total GOOD vs. Produced

12 Need to increase Visibility Find Answers to a Low OEE WHERE IS THE PAIN? How long was the process down? Main reasons for waste? Speed loss S W DT Why? compared to the ideal goal? Variation by Product, shift time or crew team?

13 System Design Meeting Key topics to OEE implementation

14 The Journey starts with one step Start small One production line or machine Expand to similar lines Automate data collection

15 The Journey starts with one step but have a destination in mind! Optimize Insights Connect 2015 General Electric Company - All rights reserved, Not for Reproduction

16 Customer Outcomes Get Connected, Get Insights, Get Optimized CONNECTED PLANT PLANT INSIGHT PLANT OPTIMIZATION No unplanned downtime Increase efficiency, and manage risk Optimize profitability 8% equipment productivity 13% cycle time productivity 18% WIP and inventory 70% OTD time 12% rework/waste, 15% warranty costs 2015 General Electric Company - All rights reserved, Not for Reproduction

17 Packing Line #1 Design Focus Filler Fully Automated Data Available Packer Some Automated Data Palletizer All manual work

18 Packing Line #1 Manual Collection Downtime Tracker Sheet Guidelines for sheet: Keep track of downtime events over five (5) minutes If minor issue occurs frequently, estimate the duration for the hour Start Time End Time Type Reason Comments 8:15 8:50 Maint Motor keeps failing 9:20 9:35 Ops Blockage on conveyor 9:50 10:00 Ops Opened safety door several times today

19 Downtime Reason Tree Design [Type] Production Planned Restraints [Reason] Maintenance Operations Required Scheduled Off External [Detail] Filter Motor Clog Bottle Jam Prev Maint Change Over Blocked Starved [Category] Availability (major stops) Performance (minor stops) Removed from Calendar (outside of OEE)

20 Packing Line #1 Automated Data Filler Downtime Run Status and Fault Signals Waste Several Kickoff Counters Production Counters Running Stopped Fault:

21 Automated Faults [Type] [Reason] Maintenance Production Operations Planned Restraints Use fault signals Scheduled Required from the machine External Off to determine the reason [Detail] Filter Motor Clog Bottle Jam Prev Maint Change Over Blocked Starved [FAULT] FLTR_CHANGE CONV_MTR FLR_CLOG FLR_BTL_JAM [Mach Code] Code: 222 Code: 297 Code: 787 Code: 626

22 Packing Line #1 Some Automated Data Packer Downtime Status Waste No Counters Production Counters (manual over 5 mins) (record filled bins) Motor Glue Issue Fail Supplies Glue Ripped Issue Maintenance Misfeed Change Over

23 Packing Line #1 No Automation Palletizer Downtime No Data (manual over 30 mins) Waste N/A (manual status) Production Barcode scanners Inventory On Hold Rework

24 Packing Line #1 Implementation Filler Auto-Tracking Downtime, Waste and Production Packer Tracking all Downtime durations and Production Use manual entry where possible Palletizer Use barcode scanners to track inventory and status

25 Now we have Visibility Automated Data Digitized Manual Records... Control Reduced Downtime Product Quality Monitoring

26 Now we have... Standardized Reports Ready-to-go reports available on Day #1 Endless Opportunities Use powerful SQL Reports to create

27 The OEE Starter Kit G a i n V I S I B I L I T Y T a k e C O N T R O L P r e - i n s t a l l e d V i r t u a l M a c h i n e Data Archiving OEE Analytics S e r v i c e s ( 1 2 w e e k s ) Consultation sessions for OEE design Configuration to record automated data System implementation Configuration for operator interfaces, reports & dashboards Considerations for Customer-specific business logic and reporting

28 Visit Us at the Food Safety Summit Resource Center! Current Presentation Why OEE as a Metric? Learn How to Design a System to Maximize Visibility into OEE Later Today at 2:45 PM Upper Hall South, S-7632 Leverage the latest tools to ensure food safety and consistently adhere to recipes and comply with Food Safety Plans