ap06: barry callebaut: mixing in factorytalk metrics turns material loss into $500k annual net gain
Post on 13-Jul-2015
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Barry Humphries – American Canyon - USA
Barry Callebaut: Mixing in FactoryTalk® Metrics Turns
Material Loss into $500k Annual Net Gain
Background
Summary of issues American Canyon was dealing with
Aug 2012 - Feb 2013 > MUV YTD -1.18% or -$260,000 Frequent inventory adjustments Control system recipe system maintained separately to SAP Very hard to see cost impact of errors Performance reporting not real time
Shift reports Daily reports Weekly Reports
Moving bottlenecks due to process improvements Rapidly changing run rates Human Error No quick way of validating improvements
June 11, 2014 2
Where are bottlenecks?
How is BC “measuring” and “analyzing today”
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SAP Does it tell us the true reality?
One+ Is it real time Do we want to wait 24 hours to see yesterdays data
Factory Control System Too complicated Snap shot in time Time consuming!
You “Measure” and “Analyze” Now…
Typically, information is gathered manually or from various plant systems. Reports are generated in Excel
spreadsheets and distributed in paper form.
Some issues: Gathering data is tedious
and time consuming (and expensive)
Manual data collection is inaccurate
Data is “stale” at time of reporting
Data and reports are not available for analysis
Data is not detailed enough to be actionable
No time - you still have to attain today’s production goals!
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What did we want to do?
Report in real time production OEE Remove guess work from machinery utilization Link SAP info to reporting Identify bottlenecks quickly Put a cost to variance in recipes and report real time Have a flexible system that would allow fluid development Increase capacity Reduce Factory costs
June 11, 2014 5
What is FactoryTalk Metrics
Performance & Visibility FactoryTalk Metrics Benefits FactoryTalk Metrics can help you identify the true causes of inefficiency, so you can
refine, streamline, and prioritize your process improvement initiatives for maximum results. Customers often experience OEE improvements of 10-30%, but even small improvements in efficiency can add up and lead to huge bottom-line results. FactoryTalk Metrics can help you:
Increase production capacity More product, revenue, and profit in the same amount of time
Decrease manufacturing costs Less overtime, reduced labor costs, lower per-unit costs
Defer capital expenditures Make your current equipment produce more
Empower continuous improvement Automatic data collection more focused on improvement
June 11, 2014 6
FactoryTalk Metrics
Reliable, accurate, timely, automatic data collection
One place for all data
Flexible reporting that gives each user what they need
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SAP Integration
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EXPORT
ACTIONFEEDBACK
OEE and Production Data
Data collected for all monitored machines OEE and 3 components Production counts – Total, Good, Scrap Available time, Downtime, Running time Slice and dice in up to 9 dimensions for reporting
Date/time, Plant Model, Shift, Part, 5 user-defined
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Event Data to Assist with Process Improvements
FactoryTalk Metrics excels as an Event Tracking System Downtime and reasons Unproductive Time –
Blocked, Starved, Setup, etc.
Event Data can tell you Why and How Why a machine is inefficient How it is spending its time This Event report is
showing Faults and Estops – frequency and duration
Configurable, based on Machine being monitored Control system
programming
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Data Available for Analysis
Production Data KPI’s Event Data State Data Context Data
•Good Part Count•Scrap Part Count•Total Part Count• Scheduled Available
Time•Available Time•Running Time•Downtime•Faults•Faulted Time
• OEE%• TEEP• Availability%• Performance%• Quality%• Running%• Good Parts%• Scrap%• Downtime%• Available%• Fault%• Ideal Capacity• Failure Rate• Failure Frequency• MTBF• MTTR
• Event Category• Event Name• Event Reason• Event Starting Value• Event Ending Value• Event Reporting
Value• Event Severity• Event Duration• Event Occurrence
Count
• State Name• State Duration• State Occurrence
Count
• Plant Model (Enterprise/Site/ Area/Line/Workcell)
• Date/Time (Hour/Date/Day/ Week/Month/Year)
• Shift• Shift Instance• Part Id• Five User-Defined
Fields
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What Results Can You Expect?
Increased capacity More product, revenue and profit in the same amount of time
Decreased manufacturing costs Less overtime, reduced labor costs
Deferred capital expenditures Make your current equipment produce more
Decreased cost of quality Improved quality Lower material costs
Decreased overhead costs Save time in collecting data and preparing reports
Efficiency improvements of 10-40% are typical!
Run Time
Major Equipment Run Time
Number of starts
Case Weights
Case Weights
OEE Molding Lines
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OEE Molding Lines
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OEE Liquid Line
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OEE Liquid line – Last 7 days
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Mass Balance - MUV
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Conche Utilization
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Mixer Utilization
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Dashboards
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Case Weights
What has Been Achieved Thus far
Aug 2013 - Feb 2014 > MUV YTD +1.5% or +$140,000 Swing of $400,000
Controlled inventory adjustments with RCA Understanding of why – reduction in quantity of adjustments
Control system recipe system maintained closer to SAP Constant feedback
Cost Impact of changes visible instantly Real Time tailored reports Tracking of bottlenecks Increasing run rates More accurate data entry Solid way of validating improvements
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