Efficiency monitoring

In order to be able to talk about continuous improvement of productivity, it is necessary to know where this improvement can take place, or where the criticality occurs.

All this information can be acquired by monitoring specific KPI such as:

  • number of downtimes
  • process performance (speed)
  • number of non-compliances (waste)

 

Andon and OEE

There are two tools for monitoring the efficiency of a production process: Andon and OEE (Overall Equipment Effectiveness).

These are two tools (software) that work in perfect synergy: the first one to highlight the real-time production trend; the second one to allow a detailed and in-depth analysis of the production, in the short and medium interval.

The calculation of the OEE makes it possible to identify and quantify the main plant production losses and monitor the efficiency of production processes:

  • Provides a picture of the actual production situation
  • Highlights the causes of waste
  • Identifies where wastes occur most often
  • It represents a valid support tool for decision makers

Pratically…

 

¬ęOEE is the fact-finding tool that should be present in every company¬Ľ

Efficiency KPI

We talked about specific KPI. Let’s see exactly what we are monitoring.

Controlling the number of downtimes means verifying their availability, that is how much of the total available time (i.e. the total time without the breaks that are already scheduled) is actually used by the machine at work.

 

OEE calculation diagram

OEE calculation diagram

 

The stop can be recorded entirely by the machine or by the human operator: IMPROVE is able to manage any mode. At the end of the process, all the acquired data are synthesized and analyzed by means of a Pareto chart.

Pareto Chart of downtimes

Pareto Chart of downtimes

 

Instead the speed of the process is influenced by several factors: delays, waits… It will be useful then to understand how much of the real production time is actually used.

This type of monitoring answers the question “How am I performing when I can work?

Therefore, the data that must be taken into consideration, (and is acquired from the machine) is the number of pieces produced. The pieces produced are compared with the pieces provided through the takt time (cycle time).

Process performance

Process performance

 

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 is analyzed through a Pareto chart.

Pareto chart of non-compliant products

Pareto chart of non-compliant products

 

 

Real time efficiency monitoring

Real-time monitoring and management informs us about what is happening at this very moment. The information is conveyed through three different interfaces, two on-line for operators, and one in the office designed and reserved for management.

 

Touch panel

Present in every line, it allows the operator to record downtimes, stops due to line setting and product non-compliance. And relative causes.

The touch operator panel

The touch operator panel

 

Andon board

We remain in line, where we also find a LED TV (the Andon board), clearly visible, which displays all the data that allow us to understand how production is going at that very moment. We therefore have the takt time of the current production order, the expected prices the produced prices, the good first-time pieces, the detail of the efficiency of each of the three KPIs and the total OEE.

Andon board

Andon board

The aggregated display of the data

The management has access from its own office to interfaces specifically designed to allow them to view the aggregated information relating to performance, downtime and quality.

Aggregated display of the data

Aggregated display of the data

 

The OEE analysis

Once the data is acquired from the field, it is easy to move to a detailed analysis of what happened and why, to enable the continuous improvement processes. The analysis can take place on the day, or on the current month.

 

The OEE analysis

The OEE analysis

 

  • In the central part of the screen we find the percentage values of the OEE and the three performance indicators (stops, availability and waste).
  • It is possible to consult the system for a daily (the data is scanned on an hourly basis), or monthly period (the data is scanned on a daily basis).
  • In the lower part we have the Pareto of stops and waste.

Speaking of Industry 4.0…

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 factories located also in different parts of the world.

The assigned manager will then be able to compare the production efficiency of different plants in relation to a specific product.

The OEE overview

The OEE overview

 

But above all, the OEE is an essential prerequisite, in order to open discussions and start projects concerning 4.0. Efficiency monitoring should be a tool present in every company, without which talking about smart factory is the same as building without laying the foundations.

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La NeXT è una software house che produce e commercializza sistemi informatici studiati per fornire informazioni e dati aggregati al management aziendale, supportandolo nelle decisioni operative.

La NeXT può garantire una eccellente qualità del servizio, grazie alla tecnologia della programmazione ad agenti, unica nel settore.

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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.

Where to find us

Operational headquarter:via Ancona 55/A 60030, Castelbellino (AN)
Registered office: via Nazario Sauro 11/a 60035, Jesi (AN)
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