To be able to talk about continuous improvement, it is necessary to know where this improvement can take place, or where the critical issues occur.
All this information can be acquired by monitoring KPI such as:
- Availability (machine stops)
- Process performance (speed)
- Quality (number of scraps)
Andon and OEE
There are two methods to monitor the efficiency of a production process: the Andon and OEE (Overall Equipment Effectiveness).
These are two software tools that work in perfect synergy: the first to highlight the production trend, real time; the second to allow a detailed and in-depth analysis of production, in the short and medium term.
The calculation of the OEE, in particular, makes it possible to identify and quantify the main plant production losses and monitor the efficiency of production processes:
- Provides the analysis of the current situation of production.
- Highlights the causes of waste
- Highlights where waste occurs most often
- Provides a valuable support tool for decision makers
«The OEE is the cognitive tool that should be present in every company»
We talked about specific KPIs. So let’s see what we’re going to monitor.
Checking the number of machine stops means checking the availability: understanding how much time (total time, deprived of the breaks that are already programmed) is actually used by the machine at work.
Machine stops can be recorded entirely by the machine or by human operator: IMPROVE is able to manage any mode. At the end of the process, all the acquired data are synthesized and analyzed through a Pareto chart.
The speed of the process is influenced by several factors: slowdowns, expectations .. It will be useful to understand how much of the actual production time is actually exploited.
This type of monitoring answers the question “How am I performing when I’m be able to work?”
The data taken into consideration (it is acquired by the machine), is the number of produced items. The pieces produced are compared with the expected items through the takt time.
Finally, how many compliant products are produced during the actual production time? What are the reasons for the production of waste? Also in this case, the acquired data are analyzed through a Pareto chart.
Real-time monitoring and management
Real-time monitoring and management informs us about what is happening at this moment.
The information is conveyed through three different interfaces, two for the workstation operators, and one in the office designed and reserved for management.
The touch panel
The touch panel allows the operator to change the Production Order, transfer information to the ERP, collect information on what I am producing, knowing the causes related to the production (Why I am blocked? Why is there a waste? Why am I in setup?)
The Andon board
The Andon board (a TV Led set in every workstation) shows important KPIs related to production.
- The takt time
- Produced items, expected items, residual items, of a specific production order
- Number of scraps
- Performance indicators, as a percentage
- The time bar (highlights the moments of pause and production, over time)
Aggregated data display
Management has access to specially designed interfaces to enable them to view aggregated information on performance, downtime and quality.
The OEE analysis
The IMPROVE system provides customized interfaces for different company roles.
Therefore, different people, performing different roles, have access to interfaces created ad hoc, in order to optimize the time necessary to access the information that everyone needs.
The following image shows the periodic OEE of all plant lines:
Once the data are acquired from the field, it is easy to be able to arrive at a detailed analysis of what has happened and why.
The OEE It is a detailed analysis of what happened and why, to activate processes of continuous improvement.
The analysis can take place on the day or on the current month.
The OEE periodic screen allows the immediate reading of the inefficiency trends and causes.
In the center of the screen we find the percentage values of OEE and of the three performance indicators (stops, availability and scraps).
The loss of speed is displayed blue, the loss of quality yellow and the loss caused by stops red. The percentage of OEE is green.
It’s possible to query the system for a daily period (by hour), or monthly (by day).
In the lower part of the interface, we have a Pareto graph of stops and discards.
The global OEE!
If we limit ourselves to calculate the OEE of some lines within a plant, perhaps it would not be correct to combine what we do with the concept of Industry 4.0.
What instead represents an added value, above all when the customers are multinationals, is to monitor the global production efficiency, that is everything that concerns and compares different plants located also in different parts of the world.
It’s possible to aggregate data by work stations, departments, plants … and even by corporation.
Data can be aggregated for specific areas of:
- Commodity sector
- Geographic area
The assigned manager will then be able to compare the production efficiency of different plants in relation to a specific product.
I would like to receive information regarding this solution
NeXT is a software house that produces and sells softwares developed to provide information and aggregate data to company management, supporting its operational decision making.
NeXT can guarantee excellent quality service, unique in the whole industry, thanks to agent-based technology programming.
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Registered office: via Nazario Sauro 11/a 60035, Jesi (AN)
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