Why & How to implement a data collection system. Presented by: Gerard Thissen Continuous Improvement Engineer PPF Europe Ittervoort Date :

Transcription

1 Why & How to implement a data collection system Presented by: Gerard Thissen Continuous Improvement Engineer PPF Europe Ittervoort Date :

2 The most important reason why: For Continuous Improvement purposes!!

3 Organization Performance Analyser

4 New set up of Performance Analyser Situation in the past Current situation 1. Scheduled downtime 2. Changeovers 3. Downtimes per asset (mostly (mostly generated generated automatically) automatically) 1. Scheduled downtime 2. Changeovers 3. Not machine-related (human/method/material) downtime per asset (assigned by operator) 4. Machine-related (technical) downtime per asset (assigned by operator) Change results in clear difference between technical and non technical issues

5 Advantages of this setup Better root cause analysis on issues Gives data where to focus on: Best Practice Preventive Maintenance etc.

6 Focus points Continuous Improvement NOT MACHINE RELATED downtimes Root cause analysis based on data Performance Analyser MACHINE RELATED downtimes Root cause analysis based on data Performance Analyser in combination with Maintenance Control data

7 Split in data collection Performance Analyser splits the line in two areas: - Filling department - Packaging department

8 Examples of Not machine related downtime analysis and improvement actions

9 Not machine related downtimes Packaging department 2017 YTD Cradle unloader - NOT RELEVANT DUE TO STOP OF OTHER LINE COMPONENTS IN THE FILLING DEPARTEMENT (HAS BEEN ANALYSED)

10 Not machine related downtimes Packaging department until april Micro stop - of which approx. 105 h (= 67%) due to label issues Label machine 73 mm - also due to label issue - see analysis on root cause on nextslide

11 Root cause analysis label issue Adjusting label release Bad labels (ripping, edge bonding, static) Cleaning time in between orders due to glue issues Change label container

12 Corrective action Labels diameter 73 mm On average Performance Analyser showed we have about hours downtime by labeling 400 gram cans per week Improvement Action Paper quality is changed in order to increase GE

13 Result after one month of testing with new labelpaper quality Downtime due to labelpaper: Micro stop From 20,68 h to 12,35 h downtime = 40,3% decrease of downtime on labels! Label machine 73 mm

14 Expected GE Improvement Based on the figures and the improvement actions we ve taken, we expect a GE improvement of at least 2% per year. Furthermore, we have been able to reduce operator irritations.

15 Example: NOT MACHINE RELATED Filling department 2017 YTD Cradle loader - NOT RELEVANT DUE TO STOP OF OTHER LINE COMPONENTS IN THE PACKAGING DEPARTEMENT (HAS BEEN ANALYSED)

16 Example: NOT MACHINE RELATED Filling department January 2017 January 2017 Micro stop - Is analysed in more detail. Conclusion: buffer for cradle loader not optimal

17 Modification to decrease the micro stops on the filling departement Change of material of the interlays - Decrease of micro stops due to interlays Add a second sensor on the buffer table - Full use of the buffer table, less micro stops Old situation: one sensor for both formation of the layers going into the crate and stopping the filler when the buffer is full. Also the operator had to ajust the place of the sensor when there was a change of diameter. New situation: one sensor for formation of the layers going into the crate One sensor for stopping the filler when the buffer is full. No ajustment when changing over diameter

18 Result Dowtime has been reduced March 2017 Micro stop From 19,14 h to 10,3 h downtime = 46% decrease of downtime on micro stops!

19 Result is also shown in shift report (before modification) micro stops Line speed

20 Result is also shown in shift report (after modification) Decrease of micro stops Increase of line speed

21 Examples of machine related downtime analysis and improvement actions

22 Optimization Preventive Maintenance Monthly evaluation of reliable PA data with continuous improvement on technical downtime Selection of PA data is made on TECHNICAL DOWNTIME Focus & determine where action is needed Make action plan to solve biggest problem Monthly follow up of action plan

23 Process description Data PA & MC Adjust strategy Biggest downtime RCA Define problems

24 Monthly review technical downtimes February 2017 Cradle loader February 2017

25 Ajustment Preventive Maintenance plan Define downtime topics of the asset Root cause of downtime (electrical/mechanical) Adjust PM plan

26 Downtime topics of the asset lop-sided cradles Februari 2017

27 Action plan Risk downtime high / Cradles are crooked Current maintenance once a year cradles Root Cause Analysis existing maintenance plan Review every month From yearly check to three monthly check Change maintenance plan [YES/NO]

28 Taken actions cradle problem Transport glides from cradle are bended en cradle is lop-sided Adjust compleet cradle en welding new frames under cradles (35pcs)

29 Monthly review technical downtimes March 2017 Cradle loader March 2017 From 9,1 h to 5.6 h downtime = 39% decrease of downtime on the cradle loader!

30 Further review technical downtimes March 2017 Downtime no. 1: Seamer March 2017

31 Main Time Between Failure (seamer march) 7,5 h due to defect bearing. This was an incident.

32 Action plan Broken bearing Current maintenance: every 500 production hours Seamer Root Cause Analysis existing maintenance plan Review every month Lubrication frequency doubled Change maintenance plan [YES/NO]

33 Thank you for the attention! Questions? De leverancier van dit MES system, Act-in International is vandaag ook aanwezig om eventuele vragen te beantwoorden