Total Production Management
System
Total Production Management (TPM) is a well established, successful technique used to constantly improve the effectiveness of manufacturing equipment. The key to effective TPM is reliable, accurate measurement and effective critical assessment.
Total Production Management has allowed a US manufacturer of steel cans to increase
productivity at one of their sites by installing a turnkey system
designed by Hexatec.
Using Total Production Management allows you to quickly profit from improvements in Overall Equipment Effectiveness (OEE). An OEE of 85% is considered a world class level of performance. Example OEE Report shows a simple output which quickly highlights problem areas.
TPM Auditor has been developed using the
Hexatec Audit1000 package.
Hexatec can design turnkey systems based on the TPM Auditor concept to suite your specific needs. Contact us for details.
Total Production Management
reporting can be used to quickly identify problems. The
primary statistic ‘OEE’ (Overall Equipment Effectiveness) is calculated as:
OEE = Utilisation x Efficiency x
Quality Rate [85% is world class]
Where:
| Field |
Calculation |
Highlights: |
| Utilisation
|
Actual machine run
time / actual shift time |
Breakdown,
setup and adjustment losses
|
| |
|
Planned
non-production and waiting time |
| Efficiency
|
Actual Output /
Expected Output in running time |
Idling and minor
stoppage losses |
| |
|
Reduced speed loses
|
| Quality Rate |
Actual Quality Output
/ Expected Quality Output |
Quality defects |
| |
|
Start-up yield losses |
The
example TPM Auditor system shown above was built as a total package in a ‘free-standing’ console.
Included in the box are:
-
Computer running a
standard SCAN1000 configuration and acting as both a database and web
page server to the rest of the organisation.
-
PLC with purpose-built
code and I/O to gather and pre-process data.
-
Touch screen
to provide operators with an easy-to-use tool to access valuable information with minimal training.
Simple
and speedy installation next to the production line results in minimum downtime.
The
TPM Auditor software collects machinery data in real time and
turns it into valuable information.
This
includes:
-
Utilisation
-
Efficiency
-
Quality Rate
-
Loss Measurements
-
Automatic Line Stoppage
Logging
-
Fault Logging
-
Batch Recording
All
these parameters are recorded by batch, shift and day.
The
Total Production Management System
was designed to be ‘network ready’ with an industry standard network connector so
that information from the system is on-line and accessible from anywhere in the
factory.
In
this modern age, it is important that applications from different suppliers
should be able to share information. The system is fully compliant to the latest open
standards such as OPC and Microsoft ‘Back Office’.
In
practice, this means that data from this system, including items such as the
real-time calculation of efficiencies, can be displayed on existing control room
systems.
Reporting
All
the key information is written in ‘real-time’ to database records.
Network tools allow instant access to reports.
Reports may be produced automatically or on request.
OEE
summary reports speedily highlight line problems:
OEE by Batch for dates:
17/02/99
- 18/02/99
| Batch |
Utilisation
|
Efficiency
|
Quality Rate |
OEE
|
| 381
|
50.99% |
95.07%
|
91.14% |
44.18%
|
| 382
|
50.97% |
94.80% |
91.22% |
44.08% |
| 383
|
81.78% |
95.45% |
91.84% |
71.69%
|
| 384
|
85.60% |
95.00% |
91.12%
|
74.10% |
| Averages
|
67.34% |
95.08% |
91.33% |
58.47%
|
This
report shows a low utilisation figure for batches 381
& 382.
Analysis of these batches indicates that these products caused the assembly machine to jam.
This
evidence can be used to identify problems, cost losses, re-schedule production,
etc.
Managers
now have better control of the assembly lines and can answer
with confidence:
Other Reports
Available include:
|
Batches
Report-Detailed
|
Production
by Day
|
|
Batches
Yesterday-Detailed
|
Production
by Day-Detailed
|
|
Shifts
Yesterday-Detailed
|
Production
by Shift
|
|
Last
Months Batch Production
|
Shifts
by Date
|
|
Last
Months Production by Day
|
Stoppage
by Batch-Detailed
|
|
Last
Months Shifts
|
Stoppage
by Day and Machine
|
|
OEE
Monthly
|
Stoppage
by Day and Reason
|
|
OEE
Percentage
|
Stoppage
by Machine-Detailed
|
|
OEE
Total Summary
|
Stoppage
by Reason for Selected Dates-Detailed
|
|
OEE
Batch Select Batches
|
Stoppage
History by Date-Detailed
|
|
OEE
Batch Select Dates
|
Stoppage
Log-Full History by Machine
|
|
OEE by
Shift
|
Stoppage
Log-Full History by Reason
|
|
OEE by
Date
|
Stoppage
Log-Full History by Shift
|
|
OEE
Shift Summary
|
Stoppage
Log-Full History by Shift & Machine
|
|
Utilisation
Percentage
|
Stoppage
Summary by Batch
|
|
Efficiency
Percentage
|
Stoppage
Summary by Batch & Machine
|
|
Production
by Batch
|
Stoppage
Summary by Batch & Reason
|
|
Production
by Date and Shift
|
Stoppages
by Day
|
|
Yesterdays
Batches
|
Yesterdays
Shifts
|
|
Yesterdays
Production
|
Yesterdays
Stops
|
Information is Power!!!