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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!