Author: Reckers Mechatronics

Solution to Big Losses of Manufacturing Industry : OEE

Solution to Big Losses of Manufacturing Industry :OEE

What is OEE?

OEE is basically the metric for benchmarking progress, improving effectiveness, improving the productivity and identifying losses. It is calculated as :

OEE= Availability x Performance x Quality

There are six big losses which occur in manufacturing units while production. It is considered that OEE is used to minimize those losses. The major losses are:

  • Availability Loss

a. Unplanned Stops

b. Planned Stops

  • Performance Loss

a. Small Steps

b. Reduced Speed

  • Quality Loss

a. Production Rejects

b. Startup Rejects

How to Improve Production Losses?

OEE basically aids to increase the efficiency and effectiveness of the manufacturing system. By OEE we can take the reporting in a manner that no manual intervention is there and the system is calculating the real time report of manufacturing.

By OEE we can calculate the performance of individual alongwith availability of raw material.

In Brief:

  1. OEE helps in reducing the cost of quality manufacturing in a stipulated time.
  2. It increases the effectiveness of the production.
  3. Production rate also gets improved.

How OEE works?

Sensors are placed on the machinery and they measure the relevant parameters such as temperature, pressure etc while the production line is working.

There are two ways:

  1. OEE
  2.  IIOT

    Benefits:

    OEE is useful when it helps to take the better decisions regarding how and when production line should progress.

    The concerned person can check the relevant data at any given point of time and take the decision as per the same.

     

    Direct Analysis:

    The data reaches the concerned person without manipulation and in the format as desired. No more heavy files to access for analyzing the data.

Traceability

Traceability

Traceability is the process of maintaining records of all the materials and individual parts from raw material to a finished product where a UID helps to identify a part, a batch or a finished good. In manufacturing process, the activity of collecting and managing information is known as traceability. The information is collected right from the acceptance of a raw material to shipment of that product.

We provide Automotive Industry Solutions. The solutions are provided for the following lines say Production, Inventory, Vendor etc.

Let’s take an example of Production line. On a assembly line, there are various parameters which are calculated:

traceability

 

From the above parameters Efficiency and Automation is further divided as:

OEE

 


Automation

Here by smart monitoring we refer to making the data digital through digitization or digitalization. When we convert the data from reports to computer, it is said digitization. When we convert the data from hardware such as push buttons to HMI , it is called digitalization.

 

Digitization

Whether it is digitization or digitalization , it depends upon the ground level equipment available on the assembly line. Now a days the digitization process is done with the help of Industry 4.0.

In the production line , when we talk about a particular section, there are different factors on which production depends, these are:

1. Material available

2. Operator Efficiency

3. Record Maintenance

1. Material Availability

We have developed a software , named , VM Tool which takes the input data through ERP or manually  in its Library. This Variant Management Tool is also helpful in Inventory Management of the plant.

Say, we had raw material , x

Now , after production the raw material left is y

FCVMTool

Thus,

2. Operator Efficiency

Operator Efficiency is calculated through different factors, like OEE/ANDON & Efficiency. OEE is defined as addition of following factors:

Reporting

3.  Record Maintenance

Reporting is done in various ways:



Thus, tracing can also be known as tracing in the internal system.  Every product is marked with UID, and thus when a product is traced back , one can track the raw material of the product and  this is called genealogy.

track and trace

 

 

Leveraging the power of Digitization and Connectivity

Leveraging the power of Digitization and Connectivity

Throughout the old golden days the Factory Floor is being assumed as a place with lots of machines, raw materials, man power, reports etc.

The manufacturing industries use manual reporting system to check the output product report, to check the working efficiency of the machine, to check the downtime and to check the working of process of manufacturing. Since the manual reports utilize the manpower, manipulation may take place, manual intervention can be there, no real time data is available. To overcome these challenges digitization  come into the picture.

Digitization

Digitization means collection of data from non-intelligent machines irrespective of their makes, protocols over the common platform so that each machine on the shop floor can share the required data to another machine.

Thus, digitization helps in increasing the efficiency of the manufacturing process , which in return increases the productivity and makes the manufacturing unit cost effective too.

Thus , in recent times the Factory Floor are connected into more equipped with automation and new technologies which are more focused on quality and efficiency.

The Factory floors now have clarity, speed, more efficient, cost effective, more productive, Real Time Data and all this with minimal downtime. It has now become supercharged with Automation, Industry 4.0, OEE , IIOT.

IIOT

 

The thing which leads the whole process is digitization and connectivity.

It leads towards the interconnected manufacturing , less downtime and more cost effective and efficient manufacturing times.

SCADA

 

 

Variant Management

Variant Management

Challenge:

Now a days the products are becoming customized , it leads to increase in  no. of variants. Manufacturers have to  manage assembly lines , features for customized products which is resulting in increased errors, delays in meeting customer requests and extensive rework. This all is related to Variant Management in assembly line.

Every manufacturing unit manages variants, it can be with the help of Excel Sheets or Manually. It result in long working hours, chances of errors are more, variant may get interchange with other design which in result hampers the quality of the final product. Thus, arranging multiple variants on single assembly line is becoming a challenge.

Solution:

We offered our Variant Management Solution , through which the software will enable  to keep the check on production with its correct components.  This is done when barcode is scanned and matched with the RFID tag. In this the comparison is made via Plan v/s Actual.

Variant Management

Why Variant Management?

To preside over the power of reuse, reduce errors and delays and increase productivity.

In this manufacturers need to define Bill of material of a component and manage the variable in one structure rather than having individual structure. Reckers Mechatronics has designed the software, named  VM Tool , which enables one to save the variants in one structure called ‘LlBRARY’ which can save upto 5000 metrics.

Here is the dashboard of Variant Management:

SCADA SCREEN VARIANT MANAGEMENT

Advantages for the same are as follows:

  1. Plan vs  Actual can be easily checked and verified.

2. It helps to reduce the Rework.

  1. Options for each BOM is ready with the operator and can be checked also with the help of Tool.

Implementation

Firstly the data is saved in the ‘Library’ , which is build during development. It consist of the specification as per the design of the product. The Library fetches the data either through ERP or manually prepared reports.

 

VM Tool for Variant Management

There are various steps in implementation of VMS (Variant Management Software ). The steps are as follows:

  1. Order in a sequence.

2. Appropriate Information to concerned Individual.

3. Comparing Plan v/s Actual.

ERP is fed with the production plan, which is then fetched in Library , which is build during development of VM Tool. When the component comes on assembly line , the signal is transmitted to VM Tool  , the matrics related to the product comes on the screen, if it qualifies then marked as OK. Plan vs Actual is checked.

RFID TAG for variant Management

The barcode is placed on each component of the machine which is scanned and matched with the pre defined specification. ( present in the Library)

The  RFID tag is placed on each fixture which carries the unique identifier is related to the machine.

Component assembly takes place on one assembly line and engine assembly takes place on another assembly line. Further, both the components are combined to form a final desired product, which is on each stage qualified with Plan v/s  Actual.

 

Variant Management Reckers Mechatronics

ROI

The benefit of Variant Management system is to stop the Rework procedure which was time and cost consuming. Generally , customization can no longer be transferred to the customer, therefore the impetus of these losses comes on manufacturer.

 

Solutions to Industry Challenges

Solutions to Industry Challenges

Reckers Mechatronics is  Industrial Automation and Industrial digitization Solution and Service Provider organization. We are providing various solutions, few of them are:

  1. Industrial Automation
  2. Smart Productive System Solution
  3. Data Acquisitions Solutions (OEE / ENDON)
  4. M2M Interfacing
  5. Connected Enterprise Networking
  6. Intelligent Safety Solution
  7. Condition Monitoring Solutions
  8. Remote Access Solutions – Cloud Based
  9. Handshaking capability with ERP.
  10. Mechatronic Applications
  11. Robotic Solutions and many more….

We have successfully delivered solutions against some Industrial challenges like:

  1. Security or Manipulation
  2. Comparative Reports
  3. Man Management
  4. Technology Integration
  5. Data Islands

AUTOMATION

SECURITY or MANIPULATION

Challenge : 

Manual Intervention in Reports , duplicate signatures, manipulation of data

Solution Provided:

Meet Industry compliance for e.g 21 CFR Part11, Privatization of data, Real time report.

COMPARATIVE REPORTS

Challenge:

Difficult in tracing faults, difficult product back tracing

Solution Provided:

We provided digitization of equipment which lead to Real time TAG accessing and have diagnosing feature.

Also, we can provide Real time data from multiple locations.

MAN MANAGEMENT

Challenge:

The challenge is to meet the expected no. in manufacturing. Also, machine management is one of the challenge for achieving the target.

Solution Provided:

We properly utilized the available equipment and did planning at SCADA level.

 

TECHNOLOGY INTEGRATION

Challenge:

Manual data logging, synchronization of data, conventional method of OEE Calculation is one of the biggest challenges.

Solution Provided:

We basically enhance OEE by providing digital solution, controlling the performance of machine, monitoring of availability in Real Time.

DATA ISLANDS

Challenge:

The real causes of LINESTOP can be classification of Production stop, downtime, manual intervention etc.

Solution Provided:

We installed ANDON System through which we had work station information, operator become responsible for information.

It also makes the intimation to the concerned person during LINE OFF.