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

• lbowling@dstcontrols.com• Business Development Director• (707) 637-3298

Read Hayward

• rhayward@dstcontrols.com• Vice President• (707) 748-5519

DST Controls Thanks You!