benefits of collecting oee data with production tracking software

The Short and Long-Term Benefits of Automatically

Collecting OEE Data from Your Machines

Make It Better, Keep It Better

Jim Finnerty

Product Manager

Wintriss Controls Group

www.wintriss.com/sfc

http://www.wintriss.com/sfc

2/24/2017©2014 Wintriss Controls – All rights reservedSlide 2

im·prove [im-proov] verb

1. to bring into a more desirable or

excellent condition

2. to make better use of

Improvement

• All manufacturers want to improve the efficiency of

their operation

• With unlimited resources, you could improve the

productivity of every piece of equipment in your

factory

• Sadly, you don’t have unlimited resources


Improvement

• This first step toward improvement is to identify

where to focus your resources

• In order to do this, you need accurate information

about how your machines run

• “Tribal knowledge” is not enough – you need to

collect real data from your shop floor

• It’s human nature to remember catastrophic events

and ignore the mundane

• It’s the mundane stuff that’s killing you


http://www.wintriss.com/sfc/shop-floor-data-collection.html

The Goal:

• To collect data that is:

Timely

Pertinent

Accurate

Unbiased

• And make the data readily available to everyone and

everything

©2014 Wintriss Controls – All rights reserved 2/24/2017Slide 5

Data Collection – What method?

• Data can be collected manually or automatically

• Manually collected data is often biased, late, and inaccurate

• When production data is manually tracked, the person recording the information will usually do as little as possible, as quickly as possible

• If data could be collected automatically, these problems would disappear

• The problem with automatic data collection is that it’s hard to do


Controllers

• Proprietary controllers

• PLCs

• PC-based controls


Data Collection Terminal


• Installed on each machine

• Network connection

• Uses a standard protocol

• Built-in operator interface

• “Running” input

• Automatically tracks uptime

and production count data

http://www.wintriss.com/sfc/machine-monitoring-interface.html

Data Collection – What Data?

• At the very least, you should collect:

Part counts

Status (running, down, changeover, etc.) over time

Tool, job, and operator info

• This information will allow you to calculate Overall Equipment Effectiveness


What is OEE?

• OEE (Overall Equipment Effectiveness) is a "best

practices" way to monitor and improve the efficiency

of manufacturing processes

• OEE takes the most common and important sources

of manufacturing productivity loss and places them

into three primary categories

• OEE is frequently used as a key metric in Lean

Manufacturing programs


• OEE = Availability x Performance x Quality

http://wintriss.com/sfc/oee-calculation.html

What is OEE? - Availability

• Availability is the percentage of time that the machine runs, compared to the total time

• Availability takes downtime loss into account

• There is a distinction between planned and unplanned downtime

• “Planned downtime” includes lunchtime, breaks, and planned maintenance

• Unplanned downtime covers everything else


What is OEE? - Availability

• Example:

There are 480 minutes in an 8-hour shift, 960 in two shifts

With a ½ hour for lunch and two 15-minute breaks, planned downtime is 60 minutes/shift. That leaves a net available time of 840 minutes.

If at the end of two shifts, there’s been a total of 144 minutes of unplanned downtime, the availability is:


(840 minutes – 144 minutes) / 840 minutes = .83

Availability was 83%

What is OEE? - Quality

• Quality is equal to the Good Parts / Total Parts

• Example:

Out of our 30,000 parts, 600 were later rejected.


29,400 parts / 30,000 parts = .98

Quality was 98%

What is OEE? - Performance

• Performance takes into account speed loss, which

includes any factors that cause the process to operate at

less than the maximum possible speed, when running.

• For example, if a machine’s maximum operating speed is

100 SPM, the maximum production rate is 6000 parts

per hour (with a one-up die)

• If that machine is run at 75 SPM, there’s a 25% loss


What is OEE? - Performance

• Example:

The press’s maximum operating speed is 100 SPM. This

equals a maximum production rate of 6000 parts/hour.

During our (840 minutes –144 minutes) 696 minutes of

operating time, we made 30,000 parts, giving us an

actual production rate of 2586 parts/hour.


2586 parts/hour divided by 6000 parts/hour = .43

Performance was 43%

What is OEE?

• OEE = Availability x Quality x Performance


Availability (83%) x Quality (98%) x Performance (43%)

OEE = 35%

Where OEE Falls Short…

• Overly simplistic (by design)

• Difficult to average over time because jobs differ in

size (quantity & time)

• Calculations become very difficult for multiple-up

operations

• Performance calculations are skewed


OEE - Performance

• Traditional OEE uses the machine’s “Ideal Rate” to

determine performance percentage

• The Ideal Rate is the maximum machine speed, which

traditional OEE holds as the limiting factor for

performance

• For many operations, maximum machine speed is not the

limiting factor


Fixing OEE

• Instead of a single machine Ideal Rate, use different

ideal rates for each machine/part combination

• This addresses the true performance limiting factor for

each part, and accounts for multiple-up operations

• Instead of trying to “weight” jobs, simply track and

average the whole period.

• All of this is very difficult to manage manually


Fixing OEE

• An automatic system can track which job is in which

machine, and apply the appropriate ideal rate

• Rates can be automatically multiplied for multiple up

processes

• OEE can be displayed in real time as a job is running

• Different sized jobs can be appropriately weighted to

provide accurate OEE for a process over a longer period of

time


Downtime Reasons


Downtime Reasons

• In order to improve a machine’s efficiency, it is essential

that you know what is causing the downtime

• This information may be known only to the operator,

and cannot be collected automatically

• A good data collection system can coax the operator

into providing this information

• Additional functions are required at the machine


http://wintriss.com/sfc/oee-monitoring-system.html

Data Collection Terminal


• Contains a list of downtime reasons

• Tracks the duration of every

stoppage

• Inhibits further machine operation

if it stops for longer than a preset

time

• Removes the inhibit when the

operator selects a downtime

reason

Real Time Data

• An automatic data collection system provides the

most benefit shortly after it is implemented

• Specific areas for improvement are identified, and

improvements are made

• When all the improvements are made, is it possible

to still get significant benefit from the system?

• Yes. Real-time data is the gift that keeps on giving


http://www.wintriss.com/sfc/downtime-tracking-software-ROI.html

Real Time Data

• Machine status display allows personnel to quickly

respond to problems with a machine


Real Time Data

• Large format displays can be placed around the factory


Real Time Data

• Detailed job info can reduce “hidden” downtime


Remember This Slide?

• We still need to address collecting tool, job and operator details


Track Total Hits on Each Tool

• Accurate hits counts are possible


2/24/2017

Data Collection Success Stories

• A contract manufacturer was able to realize the

following benefits within six months of installation:

• Determined which jobs they needed to re-quote

(based on efficiency vs. the standard rate)

• Reduced tool maintenance-related downtime by

25% by accurately tracking hits and maintaining the

dies before they got too beat up

©2014 Wintriss Controls – All rights reserved

2/24/2017

Data Collection Success Stories

• By tracking efficiency by operator, they were able to

determine where they needed to focus their training

efforts.

• Justified a new feed purchase based on ROI from

reduced downtime

©2014 Wintriss Controls – All rights reserved

Downtime Reduction

• The automatically-generated

downtime reports indicated that an

Indiana contract stamper was

spending sixty hours per week

changing coils

• They decided to dedicate a full time

junior setup person to assist with

coil changes

2/24/2017 ©2014 Wintriss Controls – All rights reserved

http://wintriss.com/sfc/success_automotive.html

Downtime Reduction

• As a result, they were able to

reduce coil change downtime by

two-thirds

• In other words, they exchanged 40

hours of labor for 40 hours of press

uptime


More Downtime Reduction

• The same company was also

experiencing excessive downtime

caused by poor setup practices

• By providing additional training to

the setup people, they were able

to minimize setup-related

downtime like sensor faults and

straightener and feed issues



• This resulted in a 15% reduction

• They estimate that a further

downtime reduction of 9% came

from simply displaying real time data

out in the factory


Blame it on the New Guy

• A stamper is running 4 identical presses

making motor laminations

• The operators must constantly unload the

parts, so if the operator steps away, he has

to stop the machine

• The 4 machines share a common scrap

conveyor




• Each day, one of the 4 presses would

have significantly more downtime than

the other three

• It was always the same operator that

had the extra downtime

• The additional downtime was caused by

the operator stepping away from the

press to change the scrap dumpster at

the end of the conveyor



• The other three operators made him

do it because he was the new guy

• By assigning a utility person to the 4-

press cell to change the scrap

dumpster and stage coils, they reduced

downtime by 25%


• Downtime reports indicated that 15 minutes of every

hour were spent doing coil changes on large presses at

a Chicago-area metal stamper

• They knew it was bad, but the data collection software

allowed them to put hard numbers on it

• Upon review, they decided that their coil change

process was about as efficient as it was going to get



• Using the collected data, they were able to justify the

purchase of larger reels that could handle coils twice

as large

• In the end, they cut their coil change downtime in half


Downtime Reduction Team

• The same Chicago-area stamper has a group of

production and engineering people that meet weekly

to go over the “Top Ten” downtime list and identify

recurring problems

• “Waiting for QC” was a big source of downtime, so

they modified their procedures and built more gages

to allow the operators to do more QC at the machine


Downtime Reduction Team

• Using the downtime reports, they were able to

identify the operators that required additional

training

• They had the operators with the lowest downtime

number do the actual training


http://www.wintriss.com/sfc/sfcreports.html

Efficiency Improvement

• The Bottom Line:

This manufacturer was able to

increase their plant-wide OEE from

32% to 55%


Use the Data

• Once the data is collected and

placed into a database, it

becomes available to all of

your other systems

• Building a system around

standard software

components makes it easier

to share the data

• See more examples of OEE

software applications


http://www.wintriss.com/sfc/api.html

http://www.wintriss.com/sfc/machines.html

Call on Us for Assistance

• Backed by 60+ years of manufacturing experience, we

developed our first downtime data collection and

efficiency reporting software product in 1985.

• Wintriss has the expertise to help you improve your data

collection, cut down time and boost efficiency.

• Read our data collection whitepaper to learn more

Contact us by:

Calling (800) 586-8324

Scheduling a demo

Submitting a question


http://www.wintriss.com/sfc/docs/SFC_White_Paper.pdf

http://wintriss.com/sfc/contact.html

http://wintriss.com/sfc/shop-floor-software-question.html

benefits of collecting oee data with production tracking software

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