production line oee (overall equipment effectiveness)
TRANSCRIPT
Improving Plant Performance
Lonnie A. Bowling and Read Hayward
DST Controls
February 24, 2016
Overall Equipment Effectiveness
“It measures the gap between actual performance verses potential performance
for a manufacturing unit”
Why this really matters
• 10%-50% improvement in performance• Where to spend money for improvements?• Do improvements deliver the expected results?• Determining where and why performance is lost
OEE – Overall Equipment Effectiveness
OEE = Availability X Performance X Quality
Availability = 77% Performance = 95% Quality = 92%
77% x 95% x 92%
OEE a bit deeper
1. Schedule Time – when should we be running
2. Operating Time – when did we actually run
3. Ideal Cycle Time – calculated time to make a part
4. Parts Produced – actual parts produced
5. Good Parts Count – good parts produced
OEE a bit deeperAvailability = Operating Time / Schedule TimePerformance = Parts Produced / (Operating Time / Ideal Cycle Time)Quality = Good Parts Count / Parts ProducedOEE = Availability x Performance x Quality
Availability 72% x Performance 84% x Quality 78%
Getting Started – Automate Data Collection
1. Schedule Time – a set schedule and adjustments
2. Operating Time – start/stop of the machine/line
3. Ideal Cycle Time – a simple value that never changes
4. Parts Produced – sensor to count parts
5. Good Parts Count – sensor to count good or bad parts
Check List: Things that you need
1. OEE Software – like FactoryTalk Metrics2. A Server that can run the software3. A PLC that can monitor the equipment4. A network for communications5. DST to get you going!
Where can this lead?
Business Drivers:• Determining where bottlenecks occur (due to frequent process
improvements)• Performance reporting in real-time• Frequent inventory adjustment
Barry Callebaut Case Study
SolutionAutomated collection of OEE and Production Data
SolutionEvent Data to Support Process Improvements
SolutionMonitoring Case Weights
SolutionReal-Time OEE Reporting
What was Achieved
• $400,000 savings in 5 months• Better control of inventory and quality adjustments• Cost impact of changes visible instantly• Real-time reports• Validating improvements
Summary
• OEE measures the overall performance gap• OEE can start simple• Monitoring performance is critical• Automated data collection and real-time reporting is key• DST is here to help!
About DST Controls
• Located in SF Bay Area, Benicia CA• 40 Employees, 3 Divisions – Manufacturing, Controls, Data• Information Focused – Collection, Analytics, Visualization• Industrial IT Services Specialization• Rockwell Recognized Partner• Microsoft Silver Partner• CISCO Certification in Progress
Lonnie A. Bowling
• [email protected]• Business Development Director• (707) 637-3298
Read Hayward
• [email protected]• Vice President• (707) 748-5519
DST Controls Thanks You!