fundamental concepts in lean manufacturing and a key performance driver

Machine monitoring in manufacturing and in the context of OEE and improving productivity

Common production data to monitor How to Get Started With Machine Monitoring?
• Machine status – On/off, run rate, speed 1) Hardware option
• Downtime & Utilization – Planned/unplanned stops
• Quality – Right part first time (RPFT), scrap rate 2) Hardware-free option
• Operator effectiveness – Labour productivity and efficiency
• Environmental data – Humidity, vibration, temperature
• Energy – Electricity use What is OEE in Manufacturing

Five Advantages of Machine Monitoring By monitoring OEE, manufacturers can quantify and measure
equipment potential and identify sources of loss
Automated data collection
Ultimately, OEE aims to reduce waste (production losses),
The first step in manufacturing digitalization thereby lowering cost while also improving productivity
Simple, live OEE
Production visualization
Enhance shop floor communication
What Are the Common OEE Calculation & Monitoring Mistakes?
Availability
exclude too many stops from OEE calculation.

Performance
underestimate the actual production speed.

Quality
challenge of calculating the correct quality %

Top 8 OEE Calculation & Monitoring Mistakes

1. Not paying enough attention to all production stops
2. Excluding operators from the OEE implementation process
3. Using standard speed instead of design speed (Nameplate Capacity, Ideal Cycle Time)
4. Insufficient data collection
5. Focusing only on the OEE score
6. Comparing the OEE scores of different plants and machines
7. Not standardizing OEE calculation
8. Not taking action on data
How to Start With Machine Downtime Analysis?

•The single most important aspect

•Laying the groundwork for success
•No production stop left behind
•Daily check-ups
•Increasing the level of detail for machine breakdowns
How to Define Machine Breakdown Causes?
Build a framework for effective machine downtime analysis:
•Setup
• Product changeover
• Measure change
• Material change
• Setup
•Technical
• Machine reset
• Conveyor breakdown
• Robot breakdown
• Aspiration failure
• Power failure
• Lubrication failure
•Work arrangement
• Material shortage/waiting
• Material of poor quality
• Forklift wait/bringing material/taking material away
• Supplies missing/searching/waiting
• Work on another machine
• Work order/working instruction missing
•Maintenance
• Cleaning the machine
• Daily maintenance
• Weekly maintenance
• Planned maintenance
• Unplanned maintenance
• Cleaning
•Planned stops
• Pause
• Lunch
• Meeting
• Training session
Performance loss in the Six Big Losses framework

•Availability loss
• Planned stops
• Unplanned stops
•Performance loss (same as speed loss)
• Micro stops
• Slow cycles (same as slow speed)
•Quality loss
• Start-up rejects
• Production rejects
How to Measure Speed Loss – Micro Stops & Slow Speed

Slow speed is when machines or production lines run slower than the target run
rate,

Micro stops are when machines or production lines stop briefly and
frequently
How to Measure Speed Loss
– Micro Stops & Slow Speed
Countermeasures
Techniques for Tackling the Losses

1. Planned Downtime Management

2. Root Cause Analysis
3. Management Routines
4. 5S Workplace Organization
Example Dashboard
Example Solution
 Ewon Flexy

BENEFITS:
- REMOTE ACCESS AND FAULTS DIAGNOSTICS REGARDLESS OF THE MACHINE’S LOCATION
- MAINTAIN HIGHER LEVELS OF PRODUCTION AND IMPROVE OEE (OVERALL EQUIPMENT EFFICIENCY
- WEB-BASED DASHBOARD OF THE MACHINERY WITH LIVE PRODUCTION STATISTICS
Securely enable your data from your Machines
to the factory enterprise system

Flexy is OPC UA ready!