OEE on a flow line - installing your XL800 OEE system
January 28, 2009 by adrianpask
One question that comes up quite regularly when i’m demonstrating the XL800 OEE System is: “How can i get the most from an XL800 OEE System when i have more than 1 machine that i want to measure?“.
If you have 1 machine that you want to monitor, or a simple block process, the location for your XL800 OEE System is extremely obvious - you install it on either the single machine, or (and) in an area where the operators can see it easily as per this example:
XL800 OEE System on a single machine
How to get the most from XL800 OEE System on a Continuous Flow line:
If you have run a continuous flow line (typical of most food, drink, confectionary manufacture) then when we talk about XL most manufacturers say: “We want to install this on the bottleneck machine, and we also want to analyse the other machines on the line”. This presents us with a couple of technical issues; firstly XL800 is optimised to provide detailed analysis of a single machine, secondly as part of analysing a single machine you would need our LineView system to analyse the “causal downtime” i.e. the effect of your other machines on the bottleneck machine. Secondly it presents an operational issue: I know many sites that try to collect everything but don’t act on the data, and they don’t improve. To drive your OEE up - collect only what you need, as simply as possible, and act on it vigorously.
So here’s a work-around that i outline in this scenario:
- Install the XL800 OEE system on your Bottleneck machine as normal
- Install a “lack of product” signal from your infeed conveyor. This signal machines that your bottleneck machine is available to run but cannot run due to lack of product = upstream stoppage.
- Install a “build back” signal from your outfeed conveyor. This signal machines that your bottleneck machine is available to run but cannot run due to build back of product on the outfeed = downstream stoppage
- Install whatever additional faults you want on your bottleneck machine and other machines
How this will help:
- You will know the efficiency and downtime on your bottleneck machine, which is crucial
- You will know that of all the time the bottleneck is not running, how much of that time is due to upstream or downstream issues, rather than the machine just being not available.
XL800 OEE System on a Flow Line
With this information i would:
- Carry out a Short Interval Control every hour or 2 hours - SEE MY POST ON THIS HERE
- If the greatest loss to my bottleneck machine is lack or buildback then i would identify which machine has caused that loss, and why.
- If i can’t identify why or the root cause, I would put a manual tick sheet on that machine for 1 hour only and ask the operator to get some good quality downtime data.
- I would fix the root cause and review my downtime loss to the bottleneck machine
- Repeat
In my opinion one of the greatest pitfalls that a site can fall into is “I want to collect everything right now”. I promise you that if you try to collect everything you will either collect rubbish by spreading your resource to thin, or you will not be able to take action because you’re reviewing data. Collect only what you need to improve and act on it vigorously.
The more simple and elegant your initial solution, the greater the likelihood of it adding value.
OEE Journey from OptimumFX
January 26, 2009 by adrianpask
Introducing the OptimumFX OEE Journey:
One of the questions we often bounce around as a team is; “We’ve all heard of ‘The Toyota Way’, so what is ‘our way’? What is the UK FMCG way?”.
This question has pointed us in one direction - there isn’t one….so let’s create it! We’re calling this way the: “OptimumFX OEE Journey”.
Click here to download OptimumFX OEE Journey
A little bit of background: Over the last 7-8 years we’ve been developing systems such as LineView, MachineView, and more recently the XL800 OEE system, and fine tuning the processes that you can use alongside our systems to get great results. We’ve used these processes to support some of the biggest FMCG brands in the UK to get some great results.
As we move into 2009, our objective this year will be to publish these processes, document our OEE Journey, and to make our OEE systems as readily available to you as possible.
Our goals for the OptimumFX OEE Journey in 2009 are:
- Throughout 2009 OptimumFX will be publishing a number of white papers and articles to consolidate our theories for OEE improvement.
- We will be working with a number of UK Manufacturers to jointly test and publish the results from our implementations.
- Our goal is that if you want to improve OEE, we want you to be able to pick up our systems and theories, and apply them straight away.
What does this mean for you?:
- We will share our OEE Journey completely free of charge - just sign up to this blog for more details.
- XL800 OEE System trials: You can get Free Trials of our XL800 OEE Systems. Free trial of great data completely free - we’ll even help you create robust processes to get results straight away. At the end of free trial either give the system back, or buy it.
- LineView trials: Every year we intend to give one site a copy of LineView on a 6 month free trial. This year we’re working in collaboration with the “Best Factory” team from Cranfield School of Management to deliver this project. To find out more and apply follow this link: http://www.optimumfx.com/freelineview/index.html
- Or download our LineView trial document: Click here to download the LineView Trial Offer
OEE Improvement: Short Interval Control
January 25, 2009 by adrianpask
Last week i ran a series of web seminars outlining how to improve OEE by 20% using Short Interval Control techniques.
I’ve had so many requests to share the presentation i’ve uploaded it to this link here:
DOWNLOAD PRESENTATION ON OEE IMPROVEMENT WITH SIC
Contents covered:
1. OEE systems for capturing losses to OEE: LineView and XL800 from OptimumFX
2. Use of data during production
3. Your OEE “Flight path”
4. The folly of measuring OEE by looking backwards at what you’ve made
5. Picking the right measures for you and your operators
6. Issues with using manual data capture
7. Manual OEE data capture Vs Automated OEE data capture (LineView and XL800)
8. OptimumFX Productivity model
9. How to use data (OEE) to improve production
10. Short interval control process
11. Short interval control sheets
Create instant change, now.
January 23, 2009 by adrianpask
One of the questions that comes up on some forums is: “Why is the implementation of Lean/OEE activity so slow?”….or “What can we do to speed up our Lean implemenation?”.
I believe that I know a way that you can create huge, unstoppable change almost instantly.
Firstly, I would say that any improvement initiative will be very slow to implement if there’s no driving need to change. In fact i believe that if there is a big enough need to act differently, i.e. enough desire to improve or enough need to stop hurting, then change will be not just fast, it will be instantaneous. I also believe this is to be a universal human truth for all behaviour, not just manufacturing improvement.
The principles of NLP state that there are 2 key motivational factors to enable change:
- A need to move away from a current source of discomfort or pain. We call this “away” motivation.
- PLUS a desire to move towards a source of pleasure or enjoyment. We call this “towards” motivation.
**read more about motivation types at the excellent Pegasus NLP Blog**
In order to achieve change all individuals, and therefore organisations, need to have an appropriate balance of these 2 factors. Therefore, the ability of an organisation to change is directly proportional to the need for that change to be implemented, and this need is generated by combining the need to avoid particular results whilst simultaneously achieving better performance.
When the right level of “towards” and “away” motivations exist in an organisation we say that the team have ‘a burning platform’ to change. With a burning platform in place change happens. Fast. Unstoppably.
I wrote a blog about “the burning platform” a very short while ago: http://oeejourney.optimumfx.com/2008/12/17/burning-platforms-for-change/
EXAMPLES:
- I’ve worked in bottling sites that are so profitable (especially in the spirits industry) that implementing minor changes has taken >36 months.
- I’ve also worked in soft drinks sites where OEE has jumped from the low 50’s to the high 70’s in 12months.
- Most radically in a powder packaging factory where OEE jumped from 23% (and about to massively short on customer orders) to 68% in only 8 weeks.
The contributing factor in each environment is the level of pain that’s felt by the management and operator teams. In the powder packaging example they were in such deep trouble it was almost literally “change or die”. In this environment change is fast, radical, and all-consuming - infact the challenge is to slow it down and make sure the changes are sustained.
So here’s a really great question for you to ask yourself:
“How can we create the right level of need to change in our business to achieve our business and personal goals?
Improve OEE by >20% FREE web conference
January 15, 2009 by adrianpask
Would you like to improve your OEE by >20% for free?
How useful would it be for you to know how to use your production data to improve the OEE of your line by 20% for absolutely no charge?
I would like to train you FOR FREE in a process that we have helped to implement on the production of some of the world’s most famous brands. Our SHORT INTERVAL CONTROL process has helped lines add an additional >20% to their OEE over extremely short periods of time.
To accomplish this, i am hosting 5 introductory web demonstration sessions over the next week at the end of each session you will know:
- How to improve your OEE by an average of 20% using SHORT INTERVAL CONTROL with whatever data you currently have available.
- How to take your improvement to the next level by using an XL800 OEE System
These sessions are highly exclusive and i will be taking a maximum of only 16 people at a time on each session.
In each session i will be covering:
1. How to create huge OEE improvement using a Short Interval Control process
2. The KPI’s that an XL800 OEE System can help you monitor in your production process, including OEE.
3. How to use an XL800 OEE System as a visual display system (andon system) on your line with your operators
4. How your management team can use the real time reporting functionality of the XL system to prioritise actions
5. How to create shift reports for your short interval control in a matter of seconds
To get started, at 5mins before the conference is due to start, click the conference link below and follow the onscreen instructions to enter the conference. Unfortunately if there are more than 16 people present then you will have to attend another time.
The sessions are:
16th January @ 16:00 GMT
https://www2.gotomeeting.com/join/991280949
Use your microphone and speakers (VoIP) - a headset is recommended. Or, call in using your telephone.
Dial +44 (0) 203 355 7648
Access Code: 991-280-949
Audio PIN: Shown after joining the meeting
Meeting Password: xl800
Meeting ID: 991-280-949
22nd January @ 10:00 GMT
https://www2.gotomeeting.com/join/139019988
2. Use your microphone and speakers (VoIP) - a headset is recommended. Or, call in using your telephone.
Dial +44 (0) 203 355 7649
Access Code: 139-019-988
Audio PIN: Shown after joining the meeting
Meeting Password: xl800
Meeting ID: 139-019-988
22nd January @ 15:00 GMT
https://www2.gotomeeting.com/join/193241279
2. Use your microphone and speakers (VoIP) - a headset is recommended. Or, call in using your telephone.
Dial +44 (0) 203 355 7649
Access Code: 193-241-279
Audio PIN: Shown after joining the meeting
Meeting Password: xl800
Meeting ID: 193-241-279
23rd January @ 10:00 GMT
https://www2.gotomeeting.com/join/390509013
2. Use your microphone and speakers (VoIP) - a headset is recommended. Or, call in using your telephone.
Dial +44 (0) 203 051 4835
Access Code: 390-509-013
Audio PIN: Shown after joining the meeting
Meeting Password: xl800
Meeting ID: 390-509-013
23rd January @ 15:00 GMT
https://www2.gotomeeting.com/join/884044492
2. Use your microphone and speakers (VoIP) - a headset is recommended. Or, call in using your telephone.
Dial +44 (0) 203 051 4835
Access Code: 884-044-492
Audio PIN: Shown after joining the meeting
Meeting Password: xl800
Meeting ID: 884-044-492
Jidoka: Autonomation
January 15, 2009 by adrianpask
Jidoka is a term taken from The Toyota Production System and Lean Manufacturing that effectively means “intelligent automation” or “automation with a human touch”.
The purposes of jidoka are:
- To increase OEE by reducing waste
- To reduce the production of quality-inferior products
- To prevent damage to machines by causing automatic stops
- To enable your operators to focus on tasks other than just running machines
In practice Jidoka is a form of automation which prevents the production of defective products through some intelligent automation. Primarily Jidoka is a quality control process that has 4 elements:
- Detect the abnormality
- Stop
- Fix the machine or issue
- Investigate the root cause and fix
An example of Jidoka in action might be an inline quality detection system checking fill heights/weights:
- You produce a low fill - it is detected and no action is taken
- You produce 10 low fills in a minute - an alarm is sounded but no action is taken
- You produce 15 low fills in a minute - the filler is automatically stopped and an error message raised on your andon system
- With the line stopped your operator investigates the cause of the stoppage and makes a fix
In this process operators traditionally have the ability to make only very minimal tweaks to the production process settings, the majority of control is automated.
In this way applying Jidoka will help improve your OEE by increasing your Quality %.
More sophisticated versions of Jidoka can include production line control on automated continuous flow production lines. On a continuous flow line with good control, each machine will start, stop, and change speed automatically to maximise output without operator intervention. To find out more about production line control read our page here: http://oeejourney.optimumfx.com/2008/12/02/optimising-line-control/
Find out more:
Jidoka: On the Toyota website.
This jidoka website makes a great diffentiation between Autonomation and automation:
Automation is focused on labor reduction. Autonomation (Jidoka) is focused on quality improvement, and the independence of the man from the process.
Automation increases technicality, Autonomation reduces technicality. This allows skill levels to be lower in similar processes when comparing East to West. Another cost reducer!
Andon Systems and OEE improvement
January 14, 2009 by adrianpask
What are Andon systems or Andon lamps?
Andon lamps are an extremely simple system of visual management for helping teams identify when there is a problem with a process or machine. Originally they were developed as part of the Jidoka quality-control method within the Toyota Production System and have now been incorporated into standard lean manufacturing practice
Originally andon lamps were used to notify teams of a quality problem, and more frequently we see them installed on continuous flow lines to help inform operators of why machines have stopped. For example if i have an operator running two packaging machines and one of the machines stop, a simple Andon light stack can instantly tell the operator if he has a problem (and has to intervene) or if the machine has just run out of product.
Here are some sample Andon Systems courtesy of google images:
Andon lamp block
A traditional andon light stack
Andon panel with fault alarms
Andon Text display
Benefits of traditional Andon systems in your visual factory:
- Reduce reaction times for machine problems - operators see the state of machines quickly
- Reduced downtime for fault fixing - lamps indicate most common “faults” e.g. low reel, jams etc
- Improve management efficiency - Managers can quickly see which machines are stopped on a busy floor
Drawbacks of traditional Andon systems in your lean implementation:
- Signals need to be interpreted - complex systems need a code or key card to help operators remember what the alarms mean.
- Can be hard to see - if they’ve been in place for a long time lights often get damaged and dirty and can be hard to see. They can also often become ‘background noise’.
Taking Andon systems to the next level…XL800 for the ultimate visual factory
The XL800 OEE system brings Andon systems into the 21st century by taking all the strengths of existing systems, adding even more functionality, whilst keeping the core simplicity.
When you install an XL800 OEE System on your machine or line the highly visual alphanumeric display system can be used to highlight KPI’s and running conditions just like any display system.
Basic functionality:
Almost instantly the XL800 OEE system can support your lean manufacturing implementation by very quickly enabling you to show:
- MACHINE DOWN + Duration of downtime
- BREAK TIME REMAINING + Duration of break
- CHANGEOVER + Duration of changeover
More advanced functionality:
If you can get a signal from your machine to indicate why that machine has stopped then your XL800 could automatically display additional faults or alarms such as:
- Stop - Build Back (too much product on outfeed)
- Stop - Lack (no raw materials on infeed)
- Stop - No raw material
- Stop - Guards open
- Quality check due now (based on the number parts produced)
- Stop - SPECIFIC FAULT MESSAGE
- Target achieved - Good job team
- …..and the list goes on! If you can get us a signal, the XL800 OEE System can give you a display!
So what are the benefits of an XL800 as your Andon system?
- All of the benefits as traditional Andon systems
- Inform and motivate your team: by displaying real time data for how long each alarm has been triggered, and by showing targets for the production run
- Increase productivity: Simplify your shop floor - the display is 100% user configurable so you can quickly select the alarms that make the most difference to you
- Save money: Your operators will be able to respond to the right causes of machine downtime and get your machines fixed faster.
- Increase OEE: With machines being fixed faster you will produce more product than ever before
- Essential for TPM: The built in reporting and analytics software in the XL800 system is ideal for driving your TPM implementation as part of your lean journey.
Changing IT priorities in 2009?
January 12, 2009 by adrianpask
The Annual Manufacturing report 2008 which came with The Manufacturer last month and i’ve just been reading the IT section.
When this survey was taken:
73% of business said that IT was essential
When asked about priorities in the LAST 12 months companies said:
- 73% upgrading IT infrastucture
- 67% Management information systems (MIS)
- 33% system integration
- 33% Enterprise resource planning
When asked about priorities in the NEXT 12 months companies said:
- 60% Management Information Systems (MIS)
- 47% Upgrading upgrading IT infrastructure
- 40% CRM
- 33% Enterprise resource planning
For me this leads me to several conclusions and a big question.
1. A lot of companies now have an IT backbone entering 2009 that wasn’t present in 2008 - this implies to me that systems are becoming more integrated and that solutions will need to meet that requirement
2. MIS is becoming increasingly more important. We’ve been providing MIS systems targeted on OEE improvement since 2001 with our LineView system leading the way, and more recently with MachineView and XL800 and we’re certainly finding that people are far more interested in talking about MIS systems now than a few years ago. For us this means that 2009 is about making our systems known and ensuring they meet your needs with elegance and the right cost.
3. With 33% of companies in 2008 and 2009 looking at ERP systems this is very heartening - part of our focus for 2009 is in linking our LineView system up with systems such as SAP to enable demand planning (ERP) across multiple lines and multiple sites.
The million dollar/pound/yen/euro/rupee question…how has the current economic situation changed these priorities?
- For me MIS is one of the areas in which the implementation of a system can directly improve the performance of a line. Therefore if you’re looking to implement an MIS system this year then do so in the knowledge that it can directly improve your productivity, but only if your teams use it. We have a huge amount of experience in this area and are very comfortable saying that a system is only so good as how it’s used!
So let me know - how are you expecting the current economic climate to effect your business this year?
5s for Email - on leanblog.org
January 10, 2009 by adrianpask
I’ve just seen this awesome blog entry on leanblog.org by Jamie Flinchbaugh about applying 5s to your email.
Check it out here: http://www.leanblog.org/2009/01/5s-for-email.html
I’m going to do this tomorrow as i think it’s an awesome idea - i know that my colleague Samir finds my current method of ‘filing’ my emails to be particularly hilarious; i have an 800mb inbox every year of completely unsorted emails….and a huge reliance on the outlook search function!
Enjoy,
Adrian.
Innovate or die? - the brink of a revolution
January 10, 2009 by adrianpask
I’ve just been reading an article in the Food Manufacturer (Rick Pendrous, 02/01/09) in which he claims that supermarkets such as Tesco are allegedly seeking as much as a 5% price drop off products such as ready meals and other core products.
The article states “Tesco are very demanding,” said one chilled food supplier that was asked to cut its prices. “We will end up very wounded indeed.”
Are you reading this and thinking similarly? Perhaps you are already being challenged on your costs and have made the first step of laying off your temporary labour, but still being requested to hit targets and improve efficiencies. If this is the case then news that the supermarkets are going to be challenging your sales teams for further price cuts….which you are likely to be requested to deliver.
In my opinion this leaves many manufacturers with a choice: Innovate (And improve). Or die.
In my belief this environment could well lead UK manufacturing into a new era of innovation. Over the next 12-36 months i believe we will some of the things we will experience are:
- Greater demands for output
- Greater constraints on labour costs
- Greater focus on ROI
- Pressure from retaillers to drop cost
- Greater constraints on capital expenditure
Resulting in:
- Any sites that act too slowely will be shut
- Any sites that choose not to act will be shut
- Major changes for the sites that want to survive
If you want to survive expect:
- Change. Lots and lots of change
- A resurgence in lean and CI implementation
- More continuous improvement projects being implemented
- Greater focus on KPI’s and numerical performance
- Greater emphasis on improvement
- Individuals held more accountable for delivering change rather than just ‘doing the day job’
- People management skills will be at a premium
- Your site will introduce improvement projects with greater emphasis on internal team delivery
- To be involved with consultants and CI experts to support projects
If you’re slow adopting these changes my belief is that times will get very difficult…and you may not last the year, or even the next 6 months.
Many of us will have heard of “The Toyota Way” of production, when will you start to create “Your way”, and what will it contain?
The end result? I believe we are on the brink of a CI revolution in the UK. I believe that over the next 3 years we may well witness if not some new techniques, then some new ways of applying age-old techniques. I can’t wait to be involved!!!
