Manufacturing Operations Management

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Helen Peters
10 years ago
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1 Manufacturing Operations Management Paul Barber Director Lighthouse Systems

2 During this presenta.on! In over 80 Can factories In 27 countries 15 languages! 1000s of users will be using our so;ware, to:! Record quality checks Manually with simple gauges From auto-gauges, cameras React to SPC alarms! Count in real-.me Calculate production/spoilage Calculate KPIs like OEE, Utilisation%! Produce WIP and Finished Goods Pallets Print bar-code labels Track HFI pallets and manage through processes of Sorting and Scrap! Perform maintenance checks Routine checks Repairs Planned maintenance procedures

me Calculate production/spoilage Calculate KPIs like OEE, Utilisation%!

3 Who Are We?! So;ware Company! Located in UK, USA and Singapore! Standard Product: We have so;ware suite designed to support Manufacturing Opera/ons! Exper.se : We have deployed this system in Can & End plants all over the world! Recently won the pres.gious award from Frost & Sullivan for Customer Value Enhancement Award for MES in the Packaging Industry

Exper.se : We have deployed this system in Can & End plants all over the world!

4 Examples of where we work! All processes: 2 piece 3 piece Aerosols Ends Coating and Printing And many besides Pre-Forms/Bottles

5 Here to sell you IT?! YES! BUT - You already have IT solu.ons right?

6 In the future! All factory (opera.ons) data will go into one place! All users will be able to access it from wherever they are! No data will be recorded on paper! No reports manipulated in Excel! Informa.on will be immediate, live, accurate, correct! Big data will be transformed into ac.onable items! Performance, status, problems will be instantly visible to all! Users will be alerted to problems (SMS, )! Users will be guided through business processes

No reports manipulated in Excel! Informa.on will be immediate, live, accurate, correct!

7 What happens now?! Different applica.ons owned by different user groups! Gaps - Missing Applica.ons! Legacy Applica.ons 68% are struggling with inappropriate,! Paper, Filing disconnected solutions! Analysis / Reports that being don t prepared share data in Excel! IT headache - difficult and don t to deploy, share support users and maintain They are closed in terms of use and access!

8 The Emerging Strategy : ISA- 95 ERP Layer 4 Production Operations Plant Opera.ons Layer 3 - MES Quality Operations Maintenance Operations Plant Equipment (Automa.on & PLCs) Layers 0,1,2 Inventory Operations

9 MOM focuses on.! Opera/ons Targeted at shop floor users: operatives, supervisors, managers Real-time, immediate feedback Is used to drive Improved Performance Supports Continuous Improvement, Best Practice and Excellence Enforces Standard Operating Procedures (SOP s) Is linked to ERP systems

10 modules Produc/on Opera/ons Inventory Opera/ons Quality Opera/ons Maintenance Opera/ons Scheduling Job Tracking Inventory Quality Checks SPC Asset Register Down.me Produc.on Coun.ng Waste Line Log Book OEE Labour Label Prin.ng Traceability Consump.on Build Traceability Warehousing/ Logis.cs Process Monitoring Links to Documents Concerns/CAPA Supplier Complaints Customer Complaints Maintenance Management Repairs Tool Management

ng Waste Line Log Book OEE Labour Label Prin.ng Traceability Consump.

11 Manufacturing Drivers! Reduce Costs! Reduce Losses! Maintain/Improve Customer Sa.sfac.on! Maintain/Improve Quality performance! Meet Customer & Regulatory Requirements! Improve Agility/Flexibility/Responsiveness! Standardise and benchmark across plants

12 Manufacturing Opera.ons Management Production Operations! How can Shopfloor- Online help? Quality Operations Maintenance Operations Inventory Operations

13 Production Q Produc.on Repor.ng! Produc.on visualisa.on! Real-.me KPIs, e.g: Availability% (Downtime) Production Performance % Quality% (In-line spoilage & HFI) OEE% (Overall Effectiveness)! How? Take data directly from the lines/machines via PLCs M I

14 Production Q Spoilage! All Can plants report spoilage Spoilage is not only a material loss, but also lost time! How? Take data from PLCs Counts IN the process e.g. cups, blanks Counts OUT the process Camera counts Sum of pieces on pallets Counts at Reject points e.g cameras M I

but also lost time! How? Take data from PLCs Counts IN the process e.

15 Production Production Dashboard Q I M

16 Production Q M Typical Benefits I! Produc.vity by visibility & focus on KPIs! Faster reac.on.mes! Automa.c data collec.on and repor.ng Improved accuracy (no manipulation!) Improved immediacy Time savings! Support CI with history of data to analyse

17 P Quality M Quality Checks I! Operator checks Prompt operators to do the checks Record the measurements Direct connection to gauges! Auto- gauges TRAC, Versatile, Sencon, Kuhnke, SpecMetrix Systems...! Lab checks Film weights Scores

18 P Quality Gauge integra.on! Capture the measurements AND the images M I

19 P Process Parameters Quality I M! Collec.ng process parameters can be a crucial aspect of product quality.! Examples are Oven and Washer parameters! Direct connec.on to machines

20 P SPC Quality I M! All quality data is automa.cally charted (in the background)! Powerful analysis for mul.- headed processes! Strong visualisa.on! SPC limit and trend viola.ons raise alarms

21 P Quality Visualisa.on Quality I M! Visualise quality issues in the process

22 P Quality M Customer Complaints I! Customer complaints require inves.ga.ons! Where is all the data?! In the manufacturing systems!! Shopfloor- Online supports a complaints module Supporting complaint workflow Complaint investigation Complaint closure Historic analysis

23 P Inventory Q Inventory M! Tracking inventory from Goods- In to Shipping Coils Stillage WIP Finished Goods (Pallets)! Feed back to ERP

24 P Label Prin.ng Q Inventory M! Automa.cally print pallet labels on demand! Labels can be different designs

25 P Scanning, Movement, Warehouse Q Inventory M! Factory: Scan pallets at creation HFI and HFI processing! Warehouse: In-bound / Out-bound deliveries Movements State change Stock taking

26 P Maintenance Q I Maintenance! Repairs and Ad hoc work! Planned Maintenance procedures! Create maintenance WO! Organise and schedule work! Track work and spares used

27 func.onality Produc/on Opera/ons Inventory Opera/ons Quality Opera/ons Maintenance Opera/ons Scheduling Job Tracking Inventory Quality Checks SPC Asset Register Down.me Produc.on Coun.ng Waste Line Log Book OEE Labour Label Prin.ng Traceability Consump.on Build Traceability Warehousing/ Logis.cs Process Monitoring Links to Documents Concerns/CAPA Supplier Complaints Customer Complaints Maintenance Management Repairs Tool Management

28 Highlights! Visibility to all (Dashboards)! Manage by excep/on. alerts! Ease of use designed for shop floor users! One system, one set of data, one place to access, one system to support! Flexible repor/ng! Add func.onality - step by step

29 Benefits! Reduce Costs! Reduce Losses! Maintain/Improve Customer Sa.sfac.on! Maintain/Improve Quality performance! Meet Customer & Regulatory Requirements! Improve Agility/Flexibility/Responsiveness! Standardise and benchmark across plants

30 THANK YOU Please see us in the exhibi.on! USA UK Singapore

Strategy and Architecture to Establish 'Smart Plants'

Strategy and Architecture to Establish 'Smart Plants' About Intrigo We are a solu*on provider of Business Applica:ons focused on orchestra*ng Customer Value Networks in the changing SAP Enterprise technology