white paper lead by true oee - deutsche messe ag...o 12% increase in true oee within 6 months with...

© FORCAM 2016 www.forcam.com 1

WHITE PAPER

www.forcam.com

We Deliver Results In

Productivity

Lead by TRUE OEE

Smart Factory Revolution FORCAM FORCETM


WHITE PAPER

Lead By True OEE

Shop Floor Management Principles

Planned vs Actual

CIP Organisation

Shop Floor Cockpit

Smart Factory

Innovations

About FORCAM

Success Stories

Contents

We Deliver Results In Productivity

FORCAM develops solutions and concepts for the Smart Factory. Recognized as the

pioneer of the “Industry 4”, we have the courage to create new technologies and

thereby define standards for the future. We help manufacturers to remain competitive

by achieving sustainable gains in productivity and optimize resource efficiency.


Manufacturing is getting more and more complex: Products can be individualised,

production cycles are shorter and global competition stronger than ever before.

To meet these rising demands a manufacturer needs to be as efficient and as

transparent as possible. Productivity is the crucial factor for staying competitive

and securing work places.

Manufacturing and the Internet will soon be inseparable.“

Apart from real-time visualisation, Shop Floor Management systems deliver

tangible, objective data from all production assets. In order to make

improvements on the shop floor, you need these data in the form of key

performance indicators (KPIs) to use as a benchmark. Also reviewing current cycle

times and targets makes sense. Users are often surprised by automated data, as

these can be considerably different from their expectations.

Reliable data and KPIs such as Overall Equipment Effectiveness are the first step.

But how can these be leveraged to reach higher productivity and make the

improvements necessary?

Lead by TRUE OEE

How can real-time data be used?

Where are the points for improvement?

How can OEE be used as a management tool?


2. Management ToolERP systems are not suited to support the CIP organization. Real time ERP datacombined with machine data is required to visualize the real status of the shopfloor and to calculate a TRUE OEE. Planned vs. Actual Performance Analysis isthe key element of Shop Floor Management.

1. Leadership PrincipleShop Floor Management is a top-down process. Management must be trained to incorporate the CIP culture and to lead by OEE.

Shop Floor Management Principles as a Basis for „True OEE“

Traditional Method Advanced Shop FloorManagement

OEE isn‘t used as KPI as management tool.

No online visualisation.

Manual data collection(Lean Dogma: Data collected by

machine operators)

Far from RealityManagement Style:

”Management by Remote Control“

Reliable, automated and objective performance analysis.

Transparency through real-time visualisation and all KPIs at a

glance.

Based on realityManagement Style:

”Management by Process Improvement“

M a n a g e m e n t T o o l

L e a d e r s h i p P r i n c i p l e


True OEE is driven by Planned vs. Actual performance information collected in real time

The Lean Philosophy empowers the shop floor operator. The operator needs toknow what the supply chain (ERP) expects from him such as when to start an order/operation and what target must be fulfilled. Planned vs. Actual performanceinformation in real time will give the operator immediate feedback about thecurrent performance of his manufacturing workplace in order to take immediatemeasures in the case of a deviation from target.

How are you currently measuring shop floor performance?

Planned-Actual Comparison

Traditional Method Advanced Shop FloorManagement

R E A L - T I M ER E L I A B L E

D A T A

M A N U A LC O L L E C T I O N

Are there discrepancies between planned and actual set-up times?

Are there discrepancies between planned and actual cycle times?

How are you currently monitoring and tracking planned output and what is acutally produced?


Your Recipe for Success - holistic Shop Floor Management that effectively combines the most advanced Shop Floor Management System with the Lean Management philosophy.

Measuring TRUE OEE - what you cannot measure you cannot improve

Adopting Lean Management principles and leading by OEE

Creating a Continuous Improvement Process (CIP) culture with closed-loop communication

Delivering the right information to right people at the right time

Delivering planned vs. actual performance information real-time to shop floor operators

Establishing a PDCA (Plan-Do-Check-Act) cycle with actions and measures

Setting regular TRUE OEE goals for continuous improvement

Recipes for Success Shop Floor Management


Advanced Shop Floor Management (SFM) technology mustsupport all organizational roles within the CIP Organization.

All manufacturing roles are supported by advanced shop floor managementtechnology with no exceptions, from the machine operator to maintenance to theplant manager.

Continuous Improvement Process (CIP Organisation)

Foreman

Production Planning

Plant Manager

Overall Plant Performance

Maintenance

Hit lists

Drill-down analysis

Manufacturing Engineer

Production Data

Planned vs. Actual

Worker

Work OrdersWork Instructions

Machine

CIP Organisation


Periodic CIP Meetings, weekly and monthly, will utilize real time Shop Floor data to monitor, analyze, and set goals and targets for:

Stoppages / DowntimesProduction FlowOrganizationQuality

Advanced Shop Floor Management (SFM) technology offers closedloop CIP communication by delivering the right information to theright role at the right time

CIP Communication

Tools OptimizationsLogisticsWorker Orders / RoutingCurrent Turnaround / Productivity Values


Shop Floor Cockpit

Example at Audi Component Manufacturing


Cross-level OEE

OEE monitoring from machine-level, cell-level up to cross-plant OEE monitoring.

<

Plant 2 Plant 3Plant 1

Cell 2Cell 1

Machine 1 Machine 2 Machine 3 Machine 4 Machine 5

Multi-

Plant

Plant

Hall

Cell

Group

Machine

72,0% 60,0% 70,0% 40,0% 55%

66,0% 55,0%

66,5% 49,5% 51,7%

60,5%

60,5%

66,0%


World Class Shop Floor Management Create A Transparent Factory

Planning and Production are now synchronized

“Today, companies need resource efficiency in processes and in manufacturing “,

Franz Gruber, CEO FORCAM

Everything has to intertwine in a way that errors and waste can be recognizedimmediately and eliminated sustainably.

The FORCAM technology complements standard ERP-software on the planning level(top floor) using objective performance data coming directly from all factory assets(shop floor) – from one single machine to multiple plants worldwide. The efficiencyfactor of standard ERP-software is enhanced due to the real-time data capture byFORCAM.

The SMART FACTORY Starter Kit is a way to test Industry 4.0 technologies.Deployment is fast, cheap and risk-free, and can deliver increased machineavailability by 10% in the 3 month test period.

SMART FACTORY

Measuring and optimizing the performance ofmanufacturing plants anywhere, anytime

The real-time information provided by FORCAMcan be accessed through mobile gadgetsincluding smartphones and tablets.


State-Of-The-Art Shop Floor Management

Flexible web-based connectivity of a diverse number of machine controls

FORCAM‘s Factory Framework™ solution is technologically leading ManufacturingExecution System (MES). It enables improvement processes on all levels of theproduction. Factory Framework™ connects, collects, and standardizes real-time datafrom most different machine controls. For every production level, the signalsprovide comparable web-based operational states of machines and plants(production, malfunctions, and downtimes).

Innovations


State-Of-The-Art Shop Floor Management

Innovations

Results: Fast reaction with latencies in the millisecond range and high throughput.

Rule-based approach enables flexible, user-defined functions. Global deployment

potential with Unicode language support and centralized server architecture


Overall Equipment Effectiveness (OEE)

Shop Floor Management (SFM) is a strategy designed for the continuousoptimization of the plant availability by eliminating errors and waste. The mostimportant key figure to measure the performance is the OEE – Overall EquipmentEffectiveness.

As key performance indicator, OEE is the result of three factors:

o Availability

o Performance

o Quality

OEE is the most important figure (KPI) to implement the shop floor management strategy. Increasing the OEE can help speed up the ROI on your Shop Floor Management system and even

your production assets.

OEE - Three crucial performance metrics: Availability, Productivity, Quality

SFM Technology


MARKET Discrete Manufacturing Industries

PRODUCT Shop Floor Management (& Consulting)

TECHNOLOGY FORCAM FORCETM

CUSTOMERS (amongst others) Audi, BMW, Daimler, BorgWarner, MTU Aero Engines, Hilti, Mann+Hummel, WEIR Minerals

BENEFITS > Significant improvements in productivity (up to 20%)

> Accelerated Return on Investment (ROI 1 Year)

> Optimized Return on Capital Employed (ROCE)

> Improved transparency leading to lower costs

> Higher energy and resource efficiency

MANAGEMENT Former SAP Manager founded FORCAM in 2001.

Strategic investor Dietmar Hopp

Offices > Ravensburg, Germany (HQ)

> Switzerland

> England

> USA

> China

> Poland

With FORCAM customers regularly achieve increases in productivity in terms of OEE of 20% or more

FORCAM at a Glance


o Factory of the Year 2007, 2008, 2012 und 2013 (by A.T. Kearney)

o Delivering monitoring and optimization of more than 14,000 machine tools

o Audi Stamping Plants + 20% increase in TRUE OEE within 12 months

o Audi Components Plants + 10% increase in TRUE OEE within 12 months

o

o Exceeding expectations with unique shop floor management strategy

o 4.3% increase in TRUE OEE within 6 months

o 12% increase in TRUE OEE within 6 months

With FORCAM technology, elite companies have increased productivityby up to 20% within the first year, measured by TRUE Overall EquipmentEffectiveness (OEE).

Success Stories


FORCAMEUFORCAM GmbH (HQ)An der Bleicherei 1588214 Ravensburg

Tel.: +49 751/366 69 [email protected]

FORCAM LtdLumonics House

Valley Drive, RugbyCV21 1TQ, United Kingdom

[email protected] +44 (0)1788 247123

250 E. Fifth Street, 15th FloorCincinnati,

OH 45202, USA

[email protected] HQ +1 (513) 878-2780

您想联系我们？富勘（上海）软件技术有限公司

陆家嘴东路161号2613室上海市浦东新区邮编 200120, 中国

[email protected]

电话 +86 21 6869 0126

FORCAMUK

FORCAMUS FORCAMCN


COPYRIGHT 2016 BY FORCAM GMBHD-88214 Ravensburg

ALLE RECHTE VORBEHALTEN. NACHDRUCK ODER ÜBERSETZUNG, AUCH AUSZUGSWEISE NUR MIT SCHRIFTLICHER GENEHMIGUNG DER FORCAM GMBH

If you cannot measure it, you cannot improve it

Lord Kelvin

FORCAM GmbHAn der Bleicherei 1588214 RavensburgTelefon: +49 751 36669-0Fax: +49 751 [email protected]

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