Utilizing SIRM (Short Interval Results Management) and

Technology to Make Better Real Time

Decisions

Presented By: Ariel Beegle and Rodrigo Cantu

What is SIRM?

Short interval results management (SIRM) is a process for identifying and acting on opportunities to improve production

Quick and focused review of performance Show expected vs. actual performance Use of lean tools throughout the day to identify root causes and address corrective action At the end of the day, SIRM is just a report – its what you do with it that is so powerful!!

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SIRM Implementation Plan

1. Identify pilot area Line Constraint Where the rubber meets the road

2. Identify loss metrics OEE (Overall Equipment Effectiveness)

Six losses and downtime reasons

PPPH, UPPH (for highly labor oriented processes) Yield by hour (for process that suffers heavy yield losses)

3. Figure out how to get information Photo eye, Counter on machine, scale for weights

4. Create visual board / tracking tool Create a simple way of tracking the data Printed form, spreadsheet, whiteboard, flip chart, etc.

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SIRM Implementation Plan

5. Train team and start review meetings Review SIRM Training and where to get the necessary information Decide what metrics spur a huddle (below 90% to budget?) Team Leader demonstrates process to the team and does SIRM reviews for the first week- create benchmark for team Operations and Facility leaders provide coaching as needed for discussion

6. Sustain progress through audits Intent is to identify and reinforce great behavior Operations and Facility leaders should audit teams at least weekly through production walks, gemba walks, etc.

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SIRM Process

The SIRM process repeats cycles of identifying and then implementing effective actions to improve performance

Last Hour

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Now Next Hour

Best practices for SIRM Huddles

Huddles are 5 minute reviews of the board every hour when opportunities come up. Gather all available Partners for the huddle

Lead operator / production specialist Maintenance technician Team leader Quality & Sanitation (if needed)

All Partners are able to take direct action on the manufacturing process Remember to use the 5 why’s to find root cause of opportunities and document the root cause and corrective actions on the board.

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SIRM Board Visual Examples

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5:30 18oz Vanilla 2 1 1,086 541 No Mix; Partner didn’t hear page Increase vol of page in whse

6:30 18oz Vanilla 4 3 1,086 1,390

7:30 18oz Vanilla 6 6 1,086 1,400

9:30 18oz Vanilla 8 8 1,086 1,125 10:30 18oz Vanilla 10 9 1,086 682 stopped for lunch; 2 call ins

11:30 18oz Vanilla 12 11 1,086 1,084

12:30 18oz Lemon 2 1 1,800 1,366 changeover + 15 min maint fixed broken infeed

23 22 13,716 13,382

2:30 18oz Lemon 11 10 1,800 1,492 burnt cakes; oven override adjusted oven

1:30 18oz Lemon 8 8 1,800 2,197

Ice Cream Plant

VISUAL FACTORY

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Challenges

Improve manufacturing productivity

Gather actionable shop floor information

Expose problem areas

Inspire and motivate Partners

Information fast – and at fingertips

Solution

• XL800 Productivity Appliance™

• Snaps on to existing processes

• Delivers real-time performance data to all levels

• Web-based interface

Strategic – Analytics Tactical – Live Reports Operational – Scoreboard

“Six-in-One”

Visual Display Instant performance feedback

Production Monitor Plug-and-play process integration

Data Warehouse 100+ KPIs, 1,000 shifts, 1,000 jobs

I/O Processor Digital inputs, outputs and communication ports

Embedded Server Download to Excel, documentation center

Programming Platform Unlimited applications

Visual Factory Components

Production Board Wireless Scanner

Photo-eye Sensor Downtime Reason Codes

Line States

Setup Run Down Standby

Folders - Paperwork

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Current – Downtime Sheet

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Current – Minor Stops Bubble Chart

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Scans

Batch Ticket Item Barcode

Downtime Reason Code Minor Stop Reason Code

Batch Ticket Item Barcode

Production Batch Ticket

Downtime Reason Code

They Scan Downtime Reason barcode

When operator sees this …

Downtime Reason Code

Operator Scans Downtime Reason barcode

Instead of this … • START • STOP • LOST TIME • REASON

Minor Stops Reason Code

With This …

Replace This …

Reading the Board

Job Display Resets by Job

Target based on Takt Time

Actual based on Photo-eye

Efficiency = Actual / Target

Downtime for Job

Production View

Bottom half of OEE

By Part

By Shift or Part

By Shift

DOWNTIME

CHANGEOVER

CYCLE TIME

Vorne Industries, Inc. vorne

Questions

?

Thank You

Ariel Beegle

Rod Cantu