PRODUCTIVITY IMPROVEMENTS COME AS STANDARD Make an IMPACT with OEE! Section 1: What is OEE Section...

PRODUCTIVITY IMPROVEMENTS COME AS STANDARD

Make an IMPACT with OEE!

Section 1: What is OEESection 1: What is OEE

Section 2: OEE IMPACT Software + ConnectSection 2: OEE IMPACT Software + Connect

By: Gemba Solutions Ltd - Designer & Manufacturer Control Dynamics, Inc – Distributor & Integration Partner

Bringing to you OEE LEAN IMPACT Software Products

Productivity Improvements Come as Standard


Using OEE Impact Software will revolutionize the way in which you collect and analyze your manufacturing shop-floor data. its feature-rich functionality and easy to use interface enabling you to save countless man-hours over your current methods of collecting and analyzing machine performance data and bottlenecks.

OEE IMPACT has been specifically designed around the industry accepted and proven OEE Calculation standard and includes all the tools you need to measure and Impact your productivity and capacity.

However, OEE Impact goes a step further in providing a host of additional features compared to a standard OEE based solution. From the experience we have gained over many years, we have logically extended OEE IMPACT to incorporate valuable capabilities to allow the collection and analysis of virtually any efficiency data, such as: Machine / Line Set-up Time; Product Analysis; Scrap / Rejects; Re-work; Maintenance Times; etc..

It doesn’t stop there. OEE IMPACT is fully scalable and can be expanded with a number of add-on modules, including the automatic collection of data in real-time from your shop-floor assets. As a part of the LEAN Impact Suite of products OEE IMPACT will give you confidence that it will never be outgrown, making OEE IMPACT an invaluable tool now and into the future with which to manage your business.

We guarantee that OEE IMPACT will become a key component in your productivity toolbox, enabling you to get to grips with an impact:

• Machine cycle time• Machine availability• Downtime • Utilisation• Throughput• Shop Floor losses• Maintenance performance• Product performance• Mean time between failures• Bottle neck identification• Production and shift performance• Improve capacity planning• Wastage / Scrap / Rejects Analysis• Plus much, much more……..

Don’t just take our word for it. Ask for a ‘fully featured’ free trial of OEE IMPACT product today and see what your OEE figures really are.

Introduction


Key Performance Indicators

• Machine cycle times• Machine availability• Downtime • Utilization• Throughput• Shop-floor losses• Maintenance performance• Product performance• Meantime between failures• Bottleneck identification• Production and shift performance• Target capacity planning• Waste / Scrap / Rejects• Plus much, much more……..

Don’t take our word for it - ask for the ‘fully-featured’ demo of OEE IMPACT today and see what your OEE figures really are!


If you don’t measure how can you hope to manage it?If you don’t measure how can you hope to manage it?

What is OEE

The Calculation:

OEE% = Availability % x Performance% x Quality%

where:

Availability % = actual running time / planned cell production time Performance% = pieces produced / the theoretical cell production

rateQuality % = good pieces / total pieces made

No matter what type of process or manufacturing operation you are involved in and regardless of your company size you are likely to be under constant pressure to improve performance, improve quality and increase equipment availability.

Targeting any one of these three key areas for improvement, availability, performance or quality, may seem a major task and addressing all three together may seem a daunting task. However, if these areas can be addressed simultaneously, then significant improvements can be made throughout the production process. Production Output can be increased, Product Variations can be expanded and Production Cost Reductions can be achieved.

A good starting-point in attempting to achieve this is to identify and focus on simple but effective areas of the efficiency tree, areas such as asset (machine) performance which is always a hot topic. This is where OEE Analysis (Overall Equipment Effectiveness) can really help to make a difference to your productivity decision-making on a day-to-day basis.

OEE is a simple but clever calculation which focuses on individual items of process or manufacturing equipment at a finite level and allows their ‘effectiveness’ to be measured individually or in groups (i.e. with other equipment items). The OEE calculation is based on the ratio of the three key production parameters, availability, performance, and quality with time (e.g. planned shift time/s) being used as the baseline measurement.


What is OEE

OEE = Availability (B/A) X Performance (D/C) X Quality (F/E)

Planned Shift

A Planned Machine Production Time

B Actual Running Time

C Theoretical Machine Production Rate

D Actual Production Rate

E Pieces Produced

F Good Parts

Idle Time

Down Time

Speed Loss

Scrap / Rejects


Measuring OEE

• Simple system (can be achieved with manual data collection and entry system)Simple system (can be achieved with manual data collection and entry system)– Machine Status (Running or Stopped)

– Product Count

– Quality Rejects

– Simple stoppage reasons (Critical, Moderate, Non-Critical)

– Cost Effective way to produce and distribute reports to plant personnel

• More advanced (usually achieved with automated data collection system) More advanced (usually achieved with automated data collection system) – Machine Status (Running or Stopped)

– Product Count / Rates

– Quality / Rejects

– Asset Grouping

– Event Line Viewers / Dashboards

– Job Planning / Queuing / Dispatch

– Advanced Security

– Multiple Downtime Reasons categories

– HR / Machine Operator Tracking

• Why not consider a “mix & match” methodWhy not consider a “mix & match” method– Manual Data entry and Automated Collection!

– Start Small but THINK BIG Scalability


Start small but Think Big = scalability

• Manual Data CollectionManual Data Collection– Collect the data through paperwork entry forms filled in by operators

– Replace Excel or Access Software Solutions

– Analyse with OEE IMPACT

• Manual and/or Automated Data collectionManual and/or Automated Data collection– Install OEE IMPACT Connect and collect data automatically from assets.

– Analyse with OEE IMPACT in real time and Historically

Here is an example of how it would works:Here is an example of how it would works:


How OEE IMPACT Works (manual data collection)

Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators.

Configure OEE IMPACT (one time only)

Shop floor operators fill in production data forms as required.

Keyboard Production Data from Forms into OEE IMPACT Reports at anytime and/or up-date historical records as needed.


How OEE IMPACT Works (manual + Automated data collection)

Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators.

Shop floor operators fill in production data forms as required.

Configure OEE IMPACT (once only)

Input Data from Production data forms into OEE IMPACT Reports

OEE IMPACT Powerful automated reporting tool with over 200 standard reports allows easy analysis of OEE data and much more…

Automated Data Collection into OEE IMPACT Server.


Typical OEE IMPACT Connect

Ethernet+ Wi-Fi / RS485

OEE IMPACT DCT

OEE IMPACT Clients

Open Data Interface Input Data to OEE IMPACT through CSV Interface from (ERP, SCADA, DCS, Excel, SQL etc..)

Manual

Third Party InterfaceSpecific software data interfaces to SQL, OPC, SCADA, ERP, CMMS and many other interfaces to collect operational data required for OEE IMPACT data logging


OEE IMPACT Connect DCT

• OEE IMPACT CONNECT D.C.T (Data Connection OEE IMPACT CONNECT D.C.T (Data Connection Terminal)Terminal)– Price for features delivered leader in market place– Features

• Ethernet (Wi-Fi)

• Up to two serial ports (barcode reader HR Cards, RF ID etc..)

• Outputs

• Mains powered

• Compact

• Easy to configure

• Internal I/O power supply (24v)

• Expandable with data logging

• Compact design

• Can be used with LEAN IMPACT MES Systems

– Hardware Connectivity PLC’s PC’s OPC


Manual Data Entry Form

Selecting the data

entry screen

Entering scheduled downtime

OEE IMPACT will track production

runs, not just machine

performance

Production information

Downtime reasons


Production Performance

Selecting the shift

effectiveness Tab

Diagram of production

losses

Final effective production

time


Shift OEE

Shift OEE performance

OEE Summary

Production Units


Reporting Tool

• Over 200 pre-defined reports as standard• Total flexibility on reporting

– Graphical charts– Text reports

• Fast data retrieval• Export data to nearly any file or program type

– Get reports that drop into Word or Excel

• Send reports to printers, via emails and through other mediums.

The following slides provide an overview of the power offered by OEE IMPACT’s comprehensive reporting tool.

If you want to try OEE IMPACT for a limited time free of charge contact our sales team and ask for your trial copy - then you can see the true power of OEE IMPACT Reporting…


Report Generator

Selection of report type

Report Filter provides the

facility to simply drill down into the information

Selection of display options: trends, bar graphs, data grids,

units of display.Group data by Machine, shift,

product, operator Open and save commonly used

reports

Display reports in

3D


Downtime Summary

Downtime Histogram: All charts

can be user-configured


Downtime Components

Downtime can be grouped

into categories of your choice

Machine 3 has a high Idle time

Equipment failure accounts for most of

the downtime. Could be time for a planned

maintenance program!


Downtime Trend

Auto Scaling

Axis

Trend of downtime over time

Use Zoom to see more

detail


Machine Failure

Identify failure-time

per machine

Failures can be displayed as number of failures, duration, average

duration, time between

failures, MTBF, MTTR….


Simple Reject Report

Show rejects per machine by

type. OEE IMPACT allows

for as many reject types as

you need.


OEE Components

OEE IMPACT provides a vast array of tools for analysing OEE,

this being a starting point

The components

of OEE


OEE for all Machines

Most Effective Machine

Machine 6 should be

identified for a production

improvement project


OEE Time Trend

Quickly see trends and short-term problems


OEE Grid View

A Unique view of OEE

generated by OEE IMPACT

Rapidly identify production hot

spots

A grouping of poor performance on a

particular day


Production Performance

This chart shows a clear trend of falling

output

Identify the relationship of good parts to bad. Drive a

first-time-right campaign


Data Grid

All charts will flip to display the raw data.

This data can be simply cut into other

application

Sort the data on the TAB headings


Chart Editor

With the Chart Editortool you can configure and change the appearance of

the report. ADD extra analysis points; trends, averages. Import external

data


Report Summary

• In this short presentation you have seen a fraction of what the OEE IMPACT reporting tool has to offer.

• With over 200 report formats to choose from OEE IMPACT has the report you need, from simple text summary reports to complex multi-display 3D/2D charts on the same screen.

• Identify major problems quickly and use OEE IMPACT’s report generator to drill down onto the major issues.


Real Time OEE

•Enhanced Security

•Real Time Data Capture

•Production Schedules

•Real Time User Configurable Graphics

•Time Line Event Viewer

•Operator Asset Dash Board

•Data import from XML files

•Third Party Interface

•OEE Asset Grouping for lines , cells, areas, etc

•Unlimited free network users

•OEE IMPACT Data Collection Terminals DCT

The Following slides show a sample of the many expanded functions and features you get in OEE IMPACT CONNECT


Real Time Graphics

Real Time Graphics Viewer from extended menu options in OEE IMPACT CONNECT

Selectable Cell/Line production

performance Figures including OEE

Page displays are configured in 30% of the time of SCADA

systems


Line & Cell Production

Line Based Production

Cell Based OEE and

Performance Monitoring

Production trends showing in real time

as changes in today's production allowing

rapid responses


Performance Summary

Real-time OEE and Production Displays.

Red and Yellow levels of warnings

Real Time Pareto Charts

Ability to Manually Enter Downtimes and

Events

Three OEE Outputs•Shift performance to date•Performance of all jobs to date•Current Job


Event Viewer

Review •Manual•Scheduled•Automatic

EventsSpot Bottle NecksCycle TimesOperator Actions

With the correct security levels

modify recorded events


Production Schedules

Create Production Schedules for the day and allocate the Jobs to

machines, cells and lines.

Plan usingOperations and Routes for you

individual product standards


OEEIMPACT

OEE IMPACT Server (MSDE)

OEE IMPACT Connect

OEE IMPACTOEE IMPACTProduct ModulesProduct Modules

Gemba Solutions Software Product Range

LEAN IMPACT Server (SQL)

Full HR Tracking

Batch Recording

Product Tracking

Recipe Handling

Enhanced OEE

Trending

OPC

ERP Interface

+ Others

Additional LEAN IMPACT Products


Hardware & Software Requirements

• OEE IMPACT minimum recommended PC requirements:

– Software Recommended• Windows 2000 or XP (latest service packs)

– Minimum Hardware• PIII 800 or equivalent• 500 Mbyte hard disk space free• 64 Mbyte RAM• 1024x768 32 bit graphics card and monitor (preferred)• Network card (for multi-user configuration)

Please check with our technical sales team for up to date requirements.


• Price starts from only $2,995.00Price starts from only $2,995.00• Full product demonstration available.Full product demonstration available.• Manual and Real-time SolutionsManual and Real-time Solutions• Eliminate custom-built Access and Excel systems.Eliminate custom-built Access and Excel systems.• Unlimited network users (client Interface) included Unlimited network users (client Interface) included

in the price as standard.in the price as standard.• Over 200 standard reports included, together with a Over 200 standard reports included, together with a

custom report builder.custom report builder.• Easy to install, configure and use.Easy to install, configure and use.• Provides full standard OEE data entry and Provides full standard OEE data entry and

reporting as well as the ability to report OEE on reporting as well as the ability to report OEE on labor, shifts, products and much more…..labor, shifts, products and much more…..

• Understand downtime, set-up, Scrap / Rejects, Idle Understand downtime, set-up, Scrap / Rejects, Idle time, Meantime Between Failure (MTBF) + more….time, Meantime Between Failure (MTBF) + more….

• Expandable and scalable to fully features LEAN Expandable and scalable to fully features LEAN IMPACT MES System.IMPACT MES System.

• Full web and telephone support service.Full web and telephone support service.• OEE IMPACT training courses available at CDI or OEE IMPACT training courses available at CDI or

on-site at your facility.on-site at your facility.

Summary


Here is what people are saying about OEE IMPACT:Here is what people are saying about OEE IMPACT:

• “Not just another toolkit to see data”• “Configuration is easy and intuitive”.• “Data entry is a delight to use”.• “The reporting and analysis tool allows instant and outstandingly flexible reporting”• “Installation was simple and required no additional software”.• “The cost against the functions you get in OEE IMPACT are amazing”.• “Gemba Solutions have a real winner in OEE IMPACT”.• “Five network nodes ‘as standard’ allows exceptional flexibility”.• “Knowing OEE IMPACT is part of the CATS IMPACT MES Suite is a bonus”.• “OEE IMPACT is the most advanced OEE Management Software on the market”.• “Starting at $2995 this is real value for money, how does Gemba do it?”• “Well done Gemba Solutions for yet another really useful software product”.• “OEE IMPACT paid for itself in less than 2 months!”

What People Say


Make a Difference

Thank you for your time and for the opportunity !

Call our Sales team to be rushed your own fully featured OEE IMPACT Product today on the number below or request it from our web site at:

Control Dynamics, Inc.4246 Corporate Exchange DriveHudsonville, MI 49426(616) 896-2008www.cdi-mi.com

Garry Muma Mike BridleProductivity Sales Engineer (616) 896-2032 (616) 896-2030

Date post:	29-Dec-2015
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PRODUCTIVITY IMPROVEMENTS COME AS STANDARD Make an IMPACT with OEE! Section 1: What is OEE Section...

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