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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Barry Humphries – American Canyon - USA...
Background
Summary of issues American Canyon was dealing with
 Aug 2012 - Feb 2013 > MUV YTD -1.18% or -$260,000
 Freque...
How is BC “measuring” and “analyzing today”
3
 SAP
 Does it tell us the true reality?
 One+
 Is it real time
 Do we w...
You “Measure” and “Analyze” Now…
Typically, information is gathered manually or from
various plant systems. Reports are ge...
What did we want to do?
 Report in real time production OEE
 Remove guess work from machinery utilization
 Link SAP inf...
What is FactoryTalk Metrics
 Performance & Visibility
 FactoryTalk Metrics
 Benefits
 FactoryTalk Metrics can help you...
FactoryTalk Metrics
 Reliable,
accurate, timely,
automatic data
collection
 One place for all
data
 Flexible reporting
...
SAP Integration
8
EXPORT
ACTION
FEEDBACK
OEE and Production Data
 Data collected for all monitored machines
 OEE and 3 components
 Production counts – Total, Go...
Event Data to Assist with
Process Improvements
 FactoryTalk Metrics excels as
an Event Tracking System
 Downtime and rea...
Data Available for Analysis
Production Data KPI’s Event Data State Data Context Data
•Good Part Count
•Scrap Part Count
•T...
What Results Can You Expect?
 Increased capacity
 More product, revenue and profit in the same amount of time
 Decrease...
Run Time
Major Equipment Run Time
Number of starts
Case Weights
Case Weights
OEE Molding Lines
16
OEE Molding Lines
17
OEE Liquid Line
18
OEE Liquid line – Last 7 days
19
Mass Balance - MUV
20
Conche Utilization
21
Mixer Utilization
22
Dashboards
23
Case Weights
What has Been Achieved Thus far
 Aug 2013 - Feb 2014 > MUV YTD +1.5% or +$140,000
 Swing of $400,000
 Controlled invent...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
26
 On the mobile app:
1. Locate ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Please remember to tidy up your work ar...
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AP06: Barry Callebaut: Mixing in FactoryTalk Metrics Turns Material Loss into $500k Annual Net Gain

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Barry Callebaut, a global leader in chocolate production, was experiencing expensive losses of raw materials at a California plant. With no visibility to track where and when ingredient loss was occurring, the company turned to FactoryTalk Metrics software to track OEE and provide an ingredient tracking dashboard to notify operators of product losses as they occurred. The facility turned material losses into a net gain of over $500k per year. Results have captured the attention of the company COO, who has extended the system to 54 facilities across the globe.

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Transcript of "AP06: Barry Callebaut: Mixing in FactoryTalk Metrics Turns Material Loss into $500k Annual Net Gain "

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Barry Humphries – American Canyon - USA Barry Callebaut: Mixing in FactoryTalk® Metrics Turns Material Loss into $500k Annual Net Gain
  2. 2. Background Summary of issues American Canyon was dealing with  Aug 2012 - Feb 2013 > MUV YTD -1.18% or -$260,000  Frequent inventory adjustments  Control system recipe system maintained separately to SAP  Very hard to see cost impact of errors  Performance reporting not real time  Shift reports  Daily reports  Weekly Reports  Moving bottlenecks due to process improvements  Rapidly changing run rates  Human Error  No quick way of validating improvements June 11, 2014 2 Where are bottlenecks?
  3. 3. How is BC “measuring” and “analyzing today” 3  SAP  Does it tell us the true reality?  One+  Is it real time  Do we want to wait 24 hours to see yesterdays data  Factory Control System  Too complicated  Snap shot in time  Time consuming!
  4. 4. You “Measure” and “Analyze” Now… Typically, information is gathered manually or from various plant systems. Reports are generated in Excel spreadsheets and distributed in paper form. Some issues:  Gathering data is tedious and time consuming (and expensive)  Manual data collection is inaccurate  Data is “stale” at time of reporting  Data and reports are not available for analysis  Data is not detailed enough to be actionable  No time - you still have to attain today’s production goals! 4
  5. 5. What did we want to do?  Report in real time production OEE  Remove guess work from machinery utilization  Link SAP info to reporting  Identify bottlenecks quickly  Put a cost to variance in recipes and report real time  Have a flexible system that would allow fluid development  Increase capacity  Reduce Factory costs June 11, 2014 5
  6. 6. What is FactoryTalk Metrics  Performance & Visibility  FactoryTalk Metrics  Benefits  FactoryTalk Metrics can help you identify the true causes of inefficiency, so you can refine, streamline, and prioritize your process improvement initiatives for maximum results. Customers often experience OEE improvements of 10-30%, but even small improvements in efficiency can add up and lead to huge bottom-line results. FactoryTalk Metrics can help you:  Increase production capacity  More product, revenue, and profit in the same amount of time  Decrease manufacturing costs  Less overtime, reduced labor costs, lower per-unit costs  Defer capital expenditures  Make your current equipment produce more  Empower continuous improvement  Automatic data collection more focused on improvement June 11, 2014 6
  7. 7. FactoryTalk Metrics  Reliable, accurate, timely, automatic data collection  One place for all data  Flexible reporting that gives each user what they need 7
  8. 8. SAP Integration 8 EXPORT ACTION FEEDBACK
  9. 9. OEE and Production Data  Data collected for all monitored machines  OEE and 3 components  Production counts – Total, Good, Scrap  Available time, Downtime, Running time  Slice and dice in up to 9 dimensions for reporting  Date/time, Plant Model, Shift, Part, 5 user-defined 9
  10. 10. Event Data to Assist with Process Improvements  FactoryTalk Metrics excels as an Event Tracking System  Downtime and reasons  Unproductive Time – Blocked, Starved, Setup, etc.  Event Data can tell you Why and How  Why a machine is inefficient  How it is spending its time  This Event report is showing Faults and Estops – frequency and duration  Configurable, based on  Machine being monitored  Control system programming 10
  11. 11. Data Available for Analysis Production Data KPI’s Event Data State Data Context Data •Good Part Count •Scrap Part Count •Total Part Count • Scheduled Available Time •Available Time •Running Time •Downtime •Faults •Faulted Time • OEE% • TEEP • Availability% • Performance% • Quality% • Running% • Good Parts% • Scrap% • Downtime% • Available% • Fault% • Ideal Capacity • Failure Rate • Failure Frequency • MTBF • MTTR • Event Category • Event Name • Event Reason • Event Starting Value • Event Ending Value • Event Reporting Value • Event Severity • Event Duration • Event Occurrence Count • State Name • State Duration • State Occurrence Count • Plant Model (Enterprise/Site/ Area/Line/Workcell) • Date/Time (Hour/Date/Day/ Week/Month/Year) • Shift • Shift Instance • Part Id • Five User-Defined Fields 11
  12. 12. What Results Can You Expect?  Increased capacity  More product, revenue and profit in the same amount of time  Decreased manufacturing costs  Less overtime, reduced labor costs  Deferred capital expenditures  Make your current equipment produce more  Decreased cost of quality  Improved quality  Lower material costs  Decreased overhead costs  Save time in collecting data and preparing reports Efficiency improvements of 10-40% are typical!
  13. 13. Run Time Major Equipment Run Time Number of starts
  14. 14. Case Weights
  15. 15. Case Weights
  16. 16. OEE Molding Lines 16
  17. 17. OEE Molding Lines 17
  18. 18. OEE Liquid Line 18
  19. 19. OEE Liquid line – Last 7 days 19
  20. 20. Mass Balance - MUV 20
  21. 21. Conche Utilization 21
  22. 22. Mixer Utilization 22
  23. 23. Dashboards 23
  24. 24. Case Weights
  25. 25. What has Been Achieved Thus far  Aug 2013 - Feb 2014 > MUV YTD +1.5% or +$140,000  Swing of $400,000  Controlled inventory adjustments with RCA  Understanding of why – reduction in quantity of adjustments  Control system recipe system maintained closer to SAP  Constant feedback  Cost Impact of changes visible instantly  Real Time tailored reports  Tracking of bottlenecks  Increasing run rates  More accurate data entry  Solid way of validating improvements 25
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think! 26  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Please remember to tidy up your work area for the next session. We want your feedback! Please complete the session survey! Thank you for participating!
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