Introducing automated data capture
November 30, 2008 by david.evanson
This week i’ve enjoyed many extremely interesting discussions about the use of automated data capture systems in an improvement process and thought i’d share a condensation of these discussions with you.
I think most people would agree that the reason to measure performance is so that we have hard factual data with which to make the right decisions. With this data we can be assured that we’re focussing on the right area and that our precious and limited resource is working effectively to improve output. When we’re working without data then ‘gut feel’ and assumptions can mean that we’re spending our time on areas that MAY improve output….or may not. We have limited time and resource so use it wisely.
This creates a little process for us: we need to:
- Capture data - with sufficient accuracy,
- Interpret it - with sufficient speed,
- Act on it - with sufficient focus,
- Review actions using it - with sufficient detail.
As we specialise in helping sites with the steps above we often recommend automated systems as these have the advantage of being accurate, autonomous, and needing very little time invested to get instant feedback. The higher the base level of performance, the more sophisticated a measurement tool you want.
For sites that are in an OEE performance window of 40-70% we often recommend our low cost XL800 system - for £2910 (*) a site can get great quality data and eliminate the majority of the resource needed to complete and collate machine based tick sheets. For the purpose of this post i’m ignoring the huge benefits that high performing sites could get from a line based visual display system, and instead focussing on data accuracy.
For sites performing at 60%+ we often recommend our LineView or MachineView systems as they provide highly accurate data with 6 Loss analysis and full reporting and ERP integration.
So when would we recommend that you don’t use one of our systems to capture data?
Well, in these 2 discussions i had this week both individuals wanted their organisation to develop a strong in-house feel and knowledge of OEE through collecting it manually for several months:
- When the team leaders have calculated their OEE manually for several months how aware will they be of how to influence it? Extremely!
- After a team leader has spent 30mins collecting data, running calculations, and preparing reports only to report a 30% shift how important is it that they understand how to influence it? Extremely!
- With this deep knowledge and understanding in place, how valuable will these team leaders find a fully automated system which gives them accurate data, instantly, without needing to analyse operator hand writing, without the need for a calcuator? Extremely!
My personal belief is that the only way to run a modern production line is with accurate data guiding my decision making. I also believe that data and systems are only as valuable as how they’re used.
So if you’re just starting your data journey perhaps it’s worth considering not only the value of collecting data, but also the value in your teams intrinsically understanding it from hours of painful analysis - Vs the cost saving from implementing automated systems and finding some other way of getting this deep understanding.
Food for thought.
My thanks to the Gentlemen in question with whom i had these discussions - a lot of fun and very thought provoking.
*price correct as of 30th November
Using XL as a visual management scoreboard tool
October 28, 2008 by david.evanson
The first place where the XL800 will add value to your operation is on the factory floor.
Many sites first experience factory-floor visual management through the Andon systems typically found in the Toyota Production system. XL800 has much of the same functionality of a traditional Andon system with a whole load of additional reporting functionality and user-configuration. Imagine the impact that a large digital alphanumeric display can have when communicating on the factory floor.
Imagine a system which could:
- Tell you your current Takt Time is below Target
- Tell you when your Actual Speed is below TargetGive you really accurate OEE measures
- Tell you how you’ve lost output on the job/shift to that morning
- Be programmed to tell you when to do quality checks
- Count down for breaks or changeovers
- Display a “Congratulations” message when you beat that shift target
The XL system is so flexible, it will literally measure and record anything you want, and it can even be linked up to other devices. It’s even possible to:
- Activate a horn to sound at the end of break time.
- Activate a light system to indicate when a particular machine has gone down on a busy factory floor
- Trigger a buzzer when it’s time to do a quality check
- Activate an alarm when a speed/takt time dips below a minimum number
XL can do all this and far more.
XL800 and ANDON
October 23, 2008 by david.evanson
If you currently have Andon Systems installed in your plant they are providing you with an instant overview of your machine performance:
Takt Time, OEE, Downtime
- These systems tell you current status only
- If you see a machine stopped in fault you have no idea of how long it’s been stopped for
- There is no historical analysis - how often does this stop occur?
Our XL800 OEE System will provide you with all the benefits of a traditional Andon system and take this technology to a whole new level through our unique three levels of functionality:
A Visual Management Andon Scoreboard Tool:
- Give your line teams real-time feedback on performance
- Click here to find out how this can help you
A Live reporting tool:
- Enabling your management team to log on from anywhere to analyse performance in great detail
- Click here to find out how this can help you
An Accurate automated downtime reporting tool:
- Automatically generate the shift reports that your management team normally spend time creating.
- Click here to find out how this can help you
3 systems in 1 bolt-on solution
£2910
