The Platform on which to build the Lean Enterprise Improving Efficiency Real time Performance...
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The Platform on which to build the Lean Enterprise
Improving Improving Efficiency Efficiency
Real time Real time Performance Performance ManagementManagement
Fraysen Systems 2
Finbar Gallagher: BioFounder of Fraysen Systems,
20 years experience developing systems which deliver information critical to successful Lean Manufacturing.
Hewlett Packard Medical Devices
Hewlett Packard Inkjet Supplies
Tellabs Inc.
Bachelors of Science in Electronic Engineering from Dublin University
Master of Science in Systems Engineering from Boston University.
Fraysen Systems 4
The “Burning Platform”
Hourly Costs
US . . . . . . . . $21.83
Ireland . . . . . $18.80
China . . . . . . . $0.92
“China is revolutionizing the relative prices of labour, capital, goods and assets in a way that
has never happened so quickly before” – The Economist, July 28, 2005
Fraysen Systems 5
CrisisOEE%
Time
30
50
70
100
Lean with traditional IT (ERP,
MES, SCADA) & manual methods
Don’t have information to
understand issues in time to make a
difference
Fraysen Systems 6
Information is Roadblock
Too LateBlack HolesDisassociated
Can’t get the Big Picture
!!
Fraysen Systems 8
But…
Problems can be solved
Not rocket science
Resolution typically application of common sense
Perennial challenge is lack of information which is:
Complete
Specific
Trusted, and
Timely
Fraysen Systems 9
Solution
Seconds
Hours
Shifts
Days
Weeks
Minutes
Mach
ines
People
Product
Proce
ss
Mate
rial
SCADA
Real-time PerformanceManagement Systems
MES
ERP
Fraysen Systems 10
Real-Time Performance Management Systems
RPM Systems enable Manufacturers to RPM Systems enable Manufacturers to understandunderstand and and controlcontrol the the
interactioninteraction between people, equipment, between people, equipment, and product, and so manage the and product, and so manage the
operation to its maximum capacityoperation to its maximum capacity
Real-time: That which is relevant to the real-world operations of a company – “in time”, “on time”, or “right time”
Managing Automation, 2004
Fraysen Systems 11
With RPM, manufacturers can:
Sense the environment more intelligently
Predict and Prevent problems before they occur
Identify and correct problems as they occur
Business Process Change“Real time information causes you to reassess your course of action”
Gartner Group, 2005
Fraysen Systems 12
To Succeed, You Must Have
In Real-timeWith Full History
Integrated View of Whole Process
Fraysen Systems 13
Challenges
Access to all equipment / information
Equipment state mapping
Process mapping
Uncovering true management process
Agreeing common metrics
Cultural change
Fraysen Systems 14
Requirements MapRequirement
High Medium Low
Scalable: Distributed Architecture
Centralized Architecture
No High Level Architecture
Adaptable:
Configurable Product
“Simplified” Programming Tools: Visual
Basic
Classical Programming
Tools
Complete:
Direct collection from ALL
data sources
Direct collection from
some data sources: OPC
Reliant on Intermediate
Systems: MES, etc
Fraysen Systems 15
Requirements MapRequirement
High Medium Low
Real time:
Real-time Presentati
on from Real-Time
Data
Historical Reports
from Real-time Data
Reliant on Batch Level
System Sources: MES, etc
Integrated:
Integrated Process
Information Model
Single, Uniform Schema
Multiple databases /
schemas
Fraysen Systems 16
Results
“Immediately we had a very detailed view of uptime”. Within 1 week, identified and eliminated 4th highest cause of downtime.
Live data is presented in an objective manner. This exposes and prioritises problems for the team. “before it was hearsay – now we now have factual information to guide us”
Fraysen Systems 17
Results
“This is a much more efficient way to get accurate information and make better decisions”.
Enabled greater automation through higher machine reliability
Real time information directs Supervisors to where problems are: focus quickly and fix issues before they affect numbers.