3 Simple steps to getting started with XL800
July 27, 2010 by david.evanson
3 Simple steps to get your XL800 OEE System system working:
Step 1: Connect XL800 OEE System to your process
Step 2: Configure XL800 OEE System for immediate operation
Step 3: View your production in real-time
Designed for speed and simplicity – Provided ready-to-go with a standardised program
Customizable – not custom
You need to reduce downtime, but where do you start?
November 25, 2009 by david.evanson
A great place to start is focusing on your top five sources of down time. Meet with your team, pick one of the five, and brainstorm countermeasures. Next, implement the most promising countermeasures and monitor their effectiveness. Then – do it again.
XL800 makes it easy by providing you with a complete, ready-to-go solution for down time analytics that is so fast to implement you can be up and running in hours.
What are my top sources of down time? XL800 presents your top sources of down time in a simple to understand format.
How do I capture the data? XL800 automatically senses when your line goes down. Your operators simply scan a bar code for the reason. In fact, XL even generates the bar codes for you – right from its web interface. No software to install. No special printers.
How do I know if my countermeasures are working? XL800 automatically generates a trend line that clearly shows if down time is truly being reduced. You can view total down time from a historical perspective, or drill down to evaluate trends for specific down time reasons.
What else can I do? XL800 is a complete performance management solution. It provides automated, accurate real-time manufacturing
intelligence to everyone in your plant. It includes a production scoreboard that motivates your employees to “win” their shift and it
delivers web-based live production information to supervisors and managers – wherever they are.
How long does it take to install? XL800 is easy. It bolts onto your existing production process and you can be literally up and running
in hours. Instant gratification is a wonderful thing!
How much does it cost? XL800 is a great value. The flagship XL800 is £2,910 (including a deluxe plant floor scoreboard). And every
model includes our comprehensive down time tracking solution, along with other great features such as the Total Production Timeline™,
the All Production View, live reporting, OEE tracking, and much more.
What’s the next step? Here are some great options:
- Call me at +44 (0) 7545 429633 – we’ll address your specific challenges.
- Start a FREE trial – try XL800 in your plant with full OptimumFX technical support.
- Schedule an online meeting – see XL800 in action.
- Download an Executive Summary – show XL800 to your team
How can an OEE System help me improve?
September 13, 2009 by david.evanson
This is one of the main questions that we repeatedly get asked.
- So you want to record your OEE properly, how will this help me to improve?
- Or more to the point what happens if i install you system and i don’t improve?
To me there are 4 levels of use with a system such as XL to improve OEE:
1. Using the display to reduce reaction time on the line
- On a 55% line: typically 3-4% increase in efficiency based on reduced reaction time.
- This is achieved through setting up meaningful messages on the XL unit that teams react to in real time. E.g. If you regularly stop due to lack of raw materials have XL come up with a “low materials” alert prior to the machine stopping. Or perhaps program in your top 3-4 faults and have XL display a message when they occur to save precious time fault finding when the machine stops.
2. Using the reporting to carry out a structured review every 2 or 4 hours
- On a 55% line: The real area of improvement – between 3%-15% improvement through better allocation of resource during the shift
- Every 4 hours your team leader and line engineer review performance for the last 4 hours and identify what fixes need to be made to increase performance in the next 4 hours.
3. Using the reporting to carry out a structured review every 24 hours
- On a 55% line: When used with above – between 3%-10% improvement through better CI project allocation
- Review how effective the 4hr reviews were, what actions need to be picked up as a bigger project? Which teams perhaps need some coaching or support?
4. Using the reporting to carry out a structured review every week
a. On a 55% line: When used with above – between 3%-5% improvement ironing out persistent issues
When we have applied all 4 of these processes we’ve achieved OEE uplifts on 50-60% lines of between 6-8% in the first six months building to over 20% in 24 months.
In these instances the increase has been supported through a reasonable level of support and coaching (sometimes from us, sometimes done internally). The ’secret’ to success here is focus; focus on being completely dedicated to creating the processes that will work for you and your teams and not accepting any distraction that pulls you from this.
To give you a sense for how we recommend you do this:
- Typically we would work on a pilot line to create a robust process and then rollout. To get the best results we create operational champions at the level of the Factory and Operations Manager – if those people know how to use a system I guarantee the rest of the site learn very quickly!
I think that it’s entirely reasonable to expect that you would get between 3%-5% OEE improvement with very little support from us at all just based through raising awareness to downtime. If you really want to get benefit from XL I would suggest building in the relevant management review processes to ensure that the system is used regularly.
How do you get an instant feel for how your production is doing?
August 11, 2009 by david.evanson
The answer is simple - you visualize it!
You turn a jumble of numbers into an easy-to-understand picture. That’s exactly what OptimumFX XL800 OEE System delivers with the Total Production TimelineTM.
XL800 OEE System Total Production Timeline
How does it work? XL800 OEE System automatically senses if your line is running or down, and it tracks breaks and changeovers. TPTTM combines that information into a compelling visual where colour indicates state (e.g. green means running) and length indicates duration.
Who can see it? Anyone on your network. All you need is a simple web browser - there is no software to install. XL800 OEE System does the rest.
How do I get it? TPT is part of the XL800 OEE System analytics suite - it’s embedded right in the XL800 OEE System device. With our Free trial option you can even use the system commitment free for 3 months.
What else do I get? XL is a complete performance management solution. It provides automated, accurate real-time manufacturing intelligence to everyone in your plant. It includes a production scoreboard that motivates your employees to “win” their shift and it delivers web-based live production information to supervisors and managers - wherever they are.
How do I get started? Here are some options:
- Call us on +44 (0) 121 447 8520 - we’ll talk about your specific challenges.
- Start a FREE trial - try XL800 in your plant.
- Schedule an online meeting - see XL800 in action.
- Download an Executive Summary - show XL800 to your team.
XL800 OEE System: Out-of-the-box productivity improvement
Video introduction to XL800 Reporting
May 25, 2009 by david.evanson
In the video clip below you’ll find a 5 minute introduction to the XL800 OEE System Reporting features. This is our first video feature so we would massively welcome your feedback!
Plan for improving OEE with XL800 OEE System
April 21, 2009 by david.evanson
What results can you expect to get in free trial of our XL800 OEE System?
To help answer that question we have recently created a planner that you can use with your teams when you start your free trial of the XL800 OEE System.
Our intention here is to equip you with the tools necessary to get the system installed and operational as quickly as possible by engaging the key stakeholders in your site with some really clear objectives and accountabilities.
Please feel free to let me know what you think.
1. Click here to download as a pdf
2. View as an image:
Look how easy an XL800 installation is!!!
April 2, 2009 by david.evanson
We think you’ll like this - XL800 is SUCH an easy easy installation you really can get it working in hours…and in most instances we only need 3 cables wired to the board.
It really is that easy!
Literally within hours of taking it out of the box you will:
- Be monitoring your OEE
- Be monitoring your takt time and cycle times
- Be upgrading your Andon lamps with USEFUL downtime alerts not just flashing lights
- Be monitoring your total output
- Be monitoring your 3 losses to OEE - availability, quality, and performance
And this is before you even put it on your production network and start entering targets and using the other really cool features…and we haven’t even started on what you could do with the full 22 inputs we have available.
To prove just how easy the installation is, check out this pdf link below - it will show you where to take you count sensors from and the 3 cables you need to start getting great results.
Click here for the pdf link for your XL800 installation
To clarify here’s a summary of what we can give you straight out of the box:
OEE analysis signals and inputs
Plant View with XL800 OEE Systems - coming soon!
April 2, 2009 by david.evanson
Introducing our new OEE Factory Dashboard: Plant View with XL800 OEE Systems
- Would it be useful if you could look at one screen and see a summary of your entire plant OEE?
- Is it important to you to instantly know in real time how well your entire plant is running?
- Imagine how much easier it would be to allocate resource to your worse performing areas…
Now you can with our brand new “Plant View” screen
When you have multiple XL800 OEE Systems installed on your network you can instantly see the real time performance of each machine in one handy factory dashboard.
If you’re a Production Manager or an Engineering Manager you can now see the real time performance of your plant on one screen without even leaving your desk!!!
Naturally we’ll be offering this upgrade free of charge to all existing customers and will contact you directly to pass on this great new feature towards the end of April.
Click on the picture below to see it full screen:
View Multiple XL800 OEE systems on one page
As ever, we are keen to recieve your feedback - let me know what you think about this new addition.
OEE and equipment commissioning
March 30, 2009 by david.evanson
Are you thinking about investing in new production line equipment?
Would you like to avoid having your OEE demolished in the process?
Here are our 5 top tips for minimising the length of time that your line is down for the install:
1. Agree to use automated electronic measures to sign off the new equipment - most equipment suppliers we meet are very happy to sign off large projects using tick sheets and manual observation both of which are subject to significant errors. Use PLC data for the commissioning exercise - when/should the OEM argue that the numbers are incorrect at least you know that their PLC code is also incorrect!
2. Agree the range of performance metrics well in advance including a total line metric for the trial.
3. The industry standards are Mechanical Efficiency and Running Speed. We would also recommend insisting on: Mean Time Between Failure, Mean Time To Recover, OEE (Availability, Performance, Quality), and Loss to Critical/bottleneck Machine.
4. XL800 systems are extremely useful for signing off new equipment as they can be installed in a matter of hours with a completely standard setup - just bolt it on, plug it in, run the machine, and there’s your sign-off data generated completely automatically.
5. Make sure you consider the line control - we’ve seen many installations in which new equipment is installed with only the absolute minimum line control adjustments. Typically this can kill as much as 5% of your total line efficiency. Very shortly we will post our Line Control philosophy to support you here.
We’ve been involved in the commisioning of everything from individual machine upgrade to full multi-million pound production lines and hope that these simple tips help you with your install.
Incidentally i’ve just spotted this blog which also has a great post on this topic: Click Here
OEE on a flow line - installing your XL800 OEE system
January 28, 2009 by david.evanson
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.
