2013 gemba overview - maximising output minimising waste through OEE

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Gemba Solutions allows customers to understand the what, where, how, who and why of their production facility helping them to improve customer satisfaction, increase production, reduce waste, use less …

Gemba Solutions allows customers to understand the what, where, how, who and why of their production facility helping them to improve customer satisfaction, increase production, reduce waste, use less energy and reduce cost

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  • 1. Gemba Solutions Introduction
  • 2. Gemba Solutions  Proven track record in “Production Efficiency Solutions” since 1996  Combined experience of over 200 years in automation, systems development, integration, lean manufacturing & process improvement  Sector experience includes: food & drink, automotive, pharmaceutical, chemical & fmcg  UK based, centrally located in the midlands with global reach Who are we….. We are different because of the Gemba Way…… We are fanatical about making sure our customers get the benefit they’re looking for. Of course our software provides every tool necessary to run an efficient operation but the real difference is in our service, we help drive the benefit into our customers business rather than just laying software on top of it.
  • 3.  A Proper Job - we are capable, straight and effective at what we do We are responsible for our work and continuous improvement is a given. As individuals and as a company we strive to be reliable, to do the right thing, and to build our reputation by living up to the spirit of our commitments  Customer Focus - our success is based on the success of our customers Everything we do is designed to give our customers the right tools, at the right time, at the right price  Succeed for Each Other - we’re a community with a purpose Our team is built on the kind of hard work, commitment and sacrifice that only comes from mutual respect and the belief that we can do more together than we can apart.  Enduring Financial Success - as a business we expect to make a profit Our stability and our impact are dependent on generating the income that funds our dreams Our Values
  • 4. Gemba Solutions What is our purpose…….. “To improve workplace processes through technology” What solutions do we offer……. OEE IMPACT Our Windows-based solution gathers data in real-time from the plant and from the production staff and presents that data back to the users as a comprehensive set of reports, displays and analyses What services do we offer………… Gain4 Services A comprehensive set of engineering, training and continuous improvement services ensure that you get the very best from our products
  • 5. Our Customers
  • 6. We provide... Software and services that increase production efficiency These give you……. Total visibility of the what, where, when and why of your facility. In other words, we provide the tools to put you in total control of production, enabling you to be much more proactive about driving efficiency and allowing you to make informed decisions based on facts and data. Our experienced Continuous Improvement team can help you to make the best use of the solutions we provide, ensuring you get maximum benefit from your investment. Our Proposition
  • 7. A network of servers, PCs and PLCs provide a reliable backbone on which the system can run Step1: Plant identification Key Point: The plant items to be monitored ( we call these assets ) from which key manufacturing data is to be automatically gathered Enabling OEE Data Collection
  • 8. A network of servers, PCs and PLCs provide a reliable backbone on which the system can run Step 2: Plant Connection Key Point: A suitable method of plant connection is identified and implemented.  Where existing plant automation and connection to that is possible a direct link is made.  Where no suitable automation exist data collection terminals will be installed through which data can be collected Data Collection
  • 9. A network of servers, PCs and PLCs provide a reliable backbone on which the system can run Step 3: Data Logging Key Point: Data collection is linked back to a centrally located data logger this interrogates and gathers data from the automation in preparation for transmission. Data Collection Logging Data Collection Terminal (PLC) Data Collection Terminal (PLC) Existing Automation Data Logger
  • 10. A network of servers, PCs and PLCs provide a reliable backbone on which the system can run Step 3: Data Storage Key Point: Data collection is linked back to a centrally located data logger via shop floor network or corporate network, this interrogates and gathers data from the automation in preparation for transmission. Data Storage Data Collection Terminal (PLC) Data Collection Terminal (PLC) Existing Automation Data Impact Logger Data Server Logger Transmission
  • 11. A network of servers, PCs and PLCs provide a reliable backbone on which the system can run Step 4: Access Key Point: Windows workstations are deployed on the shop floor and in the office areas through which the gathered data can be viewed and analysed Data Access Data Collection Terminal (PLC) Data Collection Terminal (PLC) Existing Automation Data Impact Logger Data Server Logger Windows workstations
  • 12. Shop Floor Process Management User-configurable shop-floor overviews provide a simple mechanism through which the shop-floor team can select products, enter stoppage reasons and view current status
  • 13. Process Event Viewer
  • 14. Target Boards
  • 15. Shop Floor Area Overview
  • 16. Shop Floor Line Overview
  • 17. Visual Management and Control Optional large screens installed throughout the manufacturing area keep the shop-floor team informed on current performance and achievement against target Shop Floor Management Systems
  • 18. Shop Floor Performance Board
  • 19. Visual Management OEE Reports
  • 20. Pareto Analysis
  • 21. Comparison Analysis
  • 22. Core Module - Efficiency Tracking Labour Document Submission Gain Services Sequencing Andon Alert Process Maintenance Q/A Shopfloor Visualisation Production Toolkit
  • 23. What our Customers say……  "The product is amazing. It has changed our culture enormously on the shop-floor and we have full visibility of opportunities. Gemba have people who know OEE and all the difficulties in ensuring the metric is right for you.“ Lee Riley, PPG  The software makes it easy to spot problem areas quickly, and it offers huge value in ensuring that key decisions are taken based on factual data.” John Joyce, Gripple  "Since we have worked with Gemba I have found their working knowledge of lean and improvement activities enable us to harness tools and techniques outside of our normal working parameters to improve our business. This completes the Gemba model into a world class product and service." Tom Spragg, Barfoots of Botley  “We almost doubled our OEE in the first 6 weeks, and as a result have almost doubled our output on those assets. I am very happy with the system.” John van der Voorn, Walraven BV