CDC Factory Overview

© Copyright CDC Software

CDC Factory OverviewCDC Factory Overview

© Copyright CDC Software 2

What does CDC Factory do?

Captures performance information in real time– When the line stops / slows– When scrap / rework is produced

Presents information in Real time – Visibility across all the lines– Improving the communication

Alerts– Automatic alerts for unusual conditions– Immediate reaction to issues

Captures quality information in real time– Operator checks– Weight control checks

Driving meeting structures (Huddles)– Information to drive actions

Defines a standard set of KPI’s (Key Performance Indicators)


04/11/12© All rights reserved mvi technology Slide 3

F o o d & D r in kKerry FoodsHeinzGeest PLCGreencoreTetley teaCoors BrewersToms ConfectionaryGlanbiaManor BakeriesScottish Courage RHM IngredientsAllied Bakeries Calypso Soft drinksWeetabixWornick Foods

P a p e r , B o a r d & P r in t in gKimberly-Clark Knauf Royal Bank of ScotlandSCA HygieneBank of England printing worksKappa Packaging

A u t o m o t iv e / C o m p o n e n t sToyotaCorus Steel& AutomotiveLotus CarsNewage InternationalAGCOCaterpillarTrelleborgBMW - Body panels (for Rover)

P h a r m a /F M C GPfizer AdamsGenentechSmith & NephewKalon Decorative ProductsAmtico Warwick InternationalDupont Teijin

P o w e r /U t i l i t ie sESBiUKAEAElyo CofrethAEP EnergyAssociated British Ports

G e n e r a lSITA Tyre RecyclingFoster YeomanINCO RefineryLaporte IndustriesBio Products

Sample Customers…..

http://www.tetley.com/default.htm


Typical Pains – Shop Floor

Too much paperwork Constant & repetitive plant problems No-one does anything about issues raised No visibility of what’s happening up/downstream Unsure if on target for the shift Not sure of what to do in certain scenario’s

? ? ?


Typical Pains – Supervisor

Too much paperwork & Excel work Constant pressure to perform better Can’t prove where the problems are Don’t know why we keep missing targets No visibility of performance until after the event Difficult to make people accountable

??


Performance Measurement & Management Challenges

OEE 60%

Yield 96%

Cost / Unit $0.53

Frequent Reviews

Root Cause?

Immediate Unavoidable Action

Best Practice Operations Management

StructuredCont .Imp.

OEE 66%

Yield 98%

Cost / Unit $0.49

Behavior Change

Performance Change


Shop Floor Interface: Real Time Inputs & Performance Feedback, Management of Daily Operating Practices

!


Typical Data captured on a line

In order to capture performance, you don’t need dozens of signals– The signals that will be used for each line have been identified and will be

explained during the training classes

IN count STATUS OUT Count

REJECTTemperature Weight


Overall Equipment Effectiveness (OEE)

OEE is a measure of efficiency– Always expressed as a percentage

It tells you how your cell/factory has performed over a given period (Production Run, Shift, Specific time period)

OEE can be broken down into the 3 main elements;– Rate (of Production whilst running)– Yield (Scrap, rework, material loss)– Utilization (Up-time Vs Downtime whilst scheduled to run)


OEE - Definitions

Utilization– Of the time that we planned to run the machine, what percentage of that time did it

actually run. (Uptime Vs Downtime). Some text books may also refer to this as Availability.

Rate– While the machine actually ran, at what percentage of the predetermined rate did the

machine actually run at. Some text books may also refer to this as Performance.Yield

– What percentage of all the products produced were good products. Some text books may also refer to this as Quality.

OEE – Calculated by Multiplying the %Efficiency, by the %Rate, by the %Yield, giving an

Overall Equipment Effectiveness measure


Uptime, Downtime and Slow Running Time

Each minute, the system compares the “Rate” of production with the ‘Planned Rate’ (for the current product)

The ‘Status’ is usually based on a percentage of the Planned Rate

100%

70%

10%

Running (uptime)

Slow Running (uptime)

Stopped (downtime)

Status of Plant

% of Planned Rate

0%


Product 1 00g S trawbe rry

Count

Rate Yie ld U tilO E E

1234

100%100%

6

S TOP

7

79%

8

97%

9

93%

10

89%

‘Out-of-the-Box’ Infrastructure for a line

In

C ountS tatus

We ight

Re je ct

O ut

C ountTe m p

100%

71%

100%

71%

56%54%52%49%

OEE = Rate x Yield x Utilization

Rate = Units per min VS . s td rate

Utilization = Uptime / Net Avail time

Yield = Out / total proces sed in

S LOW


The Cell Page

Key operator interface

Designed around touch screen use

Minimal typing Easy to use Real time OEE and

task alerting


Logging a stoppage - Select the machine


Logging a stoppage - select the reason


Logging a stoppage - and that’s it!!


Logging a Quality Check – Automatic alerting

The system will alert you when a quality check is due


Logging a Quality Check – Entering the results


Logging a Quality Check – Did it Pass or Fail?


Weight Control Reporting


End Of Shift Review


Factory Dashboard

Overview of all lines

Which line requires focus

Attainment to plan

CDC Factory Overview

Business

Transcript of CDC Factory Overview