Manufacturing Operations Management Paul Barber Director Lighthouse Systems
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
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
Examples of where we work! All processes: 2 piece 3 piece Aerosols Ends Coating and Printing And many besides Pre-Forms/Bottles
Here to sell you IT?! YES! BUT - You already have IT solu.ons right?
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, email)! Users will be guided through business processes
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!
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
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
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
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
Manufacturing Opera.ons Management Production Operations! How can Shopfloor- Online help? Quality Operations Maintenance Operations Inventory Operations
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
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
Production Production Dashboard Q I M
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
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
P Quality Gauge integra.on! Capture the measurements AND the images M I
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
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
P Quality Visualisa.on Quality I M! Visualise quality issues in the process
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
P Inventory Q Inventory M! Tracking inventory from Goods- In to Shipping Coils Stillage WIP Finished Goods (Pallets)! Feed back to ERP
P Label Prin.ng Q Inventory M! Automa.cally print pallet labels on demand! Labels can be different designs
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
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
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
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
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
THANK YOU Please see us in the exhibi.on! USA UK Singapore +1-585-223-0600 +44-1293-605300 +65-6316-4370 www.lighthousesystems.com