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Improving Packaging Line Performance – Using the correct Data and Drill Down Analysis Actionable Information III www.optimumfx.com

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Page 1: Actionable information 3

Improving Packaging Line Performance –Using the correct Data and Drill Down Analysis

Actionable Information III

www.optimumfx.com

Page 2: Actionable information 3

Data…Data…Data == Good Information

Excessive data – Lack of information The right data – with drill down analysis

X

Actionable Information

Page 3: Actionable information 3

Actionable Information

1. What’s the right data to focus on the right areas?

Causal (loss to critical machine

Actual time

Machine stoppages

PDT/NOP

2. How can this be categorised in a useful way? And Why?

Six loss data

Counter-measure for

each loss

3.How can we focus our efforts ?

?

Page 4: Actionable information 3

Site

Drill Down – What it should be

Categorise Changeover Review Loss

vs Target

Cause

Machine

Fault

Review Changeover Effectiveness

Critical Machine Actual vs

Rated Speed Review Line Balance

Categorise Reject Loss

Review Loss vs Target

Page 5: Actionable information 3

Data Drill Down - Tactical LineView

Six loss

Cause pareto

Machine causal loss

Machine fault

OEE vs Total Loss

OEE60%

LineView loss screen

LineView status screens

Page 6: Actionable information 3

Data Drill Down - Strategic in LVR

Breakdowns and Minor Stops DrilldownCausal Loss Pareto

Loss Trend

Faults Pareto

Fault Trend

Page 7: Actionable information 3

Actionable Information

1. What’s the right data to focus on the right areas?

Causal (loss to critical machine

Actual time

Machine stoppages

PDT/NOP

2. How can this be categorised in a useful way? And Why?

Six loss data

Counter-measure for

each loss

3.How can we focus our efforts ?

Drill down data Real-time, Summary data & trends

?

Page 8: Actionable information 3

Problem Solving• Convergent processes

• Divergent processes

Lots of ideas or opinions

Convergent process

A specific problem or

issue in time

Divergent process

Create many different

options for action

Identify one specific action

Types of process:• Any process that funnels

your thinking• Decision Analysis• 5 Whys

Types of process:• Any process that creates

ideas• Brainstorming• Ishikawa/Fishbone

Page 9: Actionable information 3

Picking the right tool for the job

Quick and easy

Detailed and robust

Large problem

Small problem

e.g. 5 Whys

May be an individual or team event

Can be highly subjective and unrepeatable.

Ideal for providing structure for highly skilled individuals

e.g. Ishikawa/ Fishbone diagrams

Live on-going process for teams or individuals with defined outcome

Makes possible cause transparent through online documentation

Ideal for providing a structured approach for every day issues

e.g. Formal RCA/ PDCA process

Global 8D

KT Problem analysis

Typically an off-line analysis event

Highly transparent and replicable – will guide team to find new

knowledge rather than rely on existing

Ideal for tackling and closing complex issues

Page 10: Actionable information 3

Trended Data - Event in TimeData Analysis

• Downtime loss average trended up from around 250mins per week to around 350mins per week

• This happened around week commencing 2nd of February

• What changed just before this week?

Problem Solving Process

• Convergent thinking

• Suggested tool – 5 Whys

Page 11: Actionable information 3

Trended Data – Incremental Increase

Data Analysis

• Downtime loss average incrementally trended up from around less than 200mins per week to over 600mins per week

• This started happening from 2nd week of March and progressively got worse

Problem Solving Process

• Divergent thinking

• Suggested tool – Ishikawa/Fishbone

Page 12: Actionable information 3

Trended Data – Consistent High Loss

Data Analysis

• Overall the Loss has reduced from around 1000mins per week to around 700mins per week, however it is still above target, consistently high and does not show an overall downward trend

Problem Solving Process

• Divergent and then Convergent thinking

• Suggested tool(s) – Global 8D or KT Problem Analysis

Page 13: Actionable information 3

Actionable Information

1. What’s the right data to focus on the right areas?

Causal (loss to critical machine

Actual time

Machine stoppages

PDT/NOP

2. How can this be categorised in a useful way? And Why?

Six loss data

Counter-measure for

each loss

3.How can we focus our efforts ?

Drill down data Real-time, Summary data & trends

Problem solving – choose best tool