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Manufacturing Conference Workshop 3 - OEE and Energy

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OEE, overall equipment effectiveness, energy monitor, workshop

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Manufacturing Conference Workshop 3 - OEE and Energy

  1. 1. Energy Efficiency and OEE John Roberts Managing Director, Operations, Idhammar Systems 15th November 2012©Copyright 2012 Idhammar Systems Limited
  2. 2. Pan-industrial CustomersKEEPING INDUSTRY MOVING AND IMPROVING...
  3. 3. Proven Track Record in the FoodIndustryKEEPING INDUSTRY MOVING AND IMPROVING...
  4. 4. Workshop• What is OEE and how does it influence energy usage?• What information is available now?• Linking Energy usage to production and inefficiencies• Improvement Opportunities• Payback KEEPING INDUSTRY MOVING AND IMPROVING...
  5. 5. What is OEE and how does it influenceenergy usage?• A standard index of manufacturing efficiency• Based on... • Utilisation • Line availability • Manufacturing performance • Product quality• Why use it.... • Compare performance within industrial sectors • Measure of continuous improvement on a line or within a site • Highlight inefficiencies • Drive improvements in efficiency KEEPING INDUSTRY MOVING AND IMPROVING...
  6. 6. Why measure OEE?• Facilitate Continuous Improvement• Identify efficiency losses (and opportunities for improvement) in detail... • Minor stops • Slow running • Material scheduling failures • Quality issues • Line and machine downtime • ‘No Production Required’ windowsKEEPING INDUSTRY MOVING AND IMPROVING...
  7. 7. OEE: the basics 168 hour week No Scheduled Production Time Produc tion Plan No Brea Availability 65% Materi k No Staff als Dow Slow n Minor Performance 67% Runs Stops Quality 92% Rejects OEE 40% 60% Opportunity for ImprovementKEEPING INDUSTRY MOVING AND IMPROVING...
  8. 8. Gathering the data• Automated metering • Meter reference • Date & time • Meter reading• Manual • Area / Line / Asset • Date • Meter reading KEEPING INDUSTRY MOVING AND IMPROVING...
  9. 9. Monitoring Energy• Energy consultants have offered this type of service for years• They can provide • Energy consumption by site • Sometimes by zone/area • Graphs over time• Accurate analysis can be difficult due to a shortage of meters KEEPING INDUSTRY MOVING AND IMPROVING...
  10. 10. Standard Approach: Limited Meters Zone A - C, Week 01 - 2012 510 505 500 495 kWh 490 485 480 Zone A Zone B Zone C Too few meters: accurate analysis is restricted. Zone B has used the most electricity, but where and why?KEEPING INDUSTRY MOVING ANDfor a longer period? Has Zone B run IMPROVING...
  11. 11. Better: Energy Consumption by Line Lines 01 - 05, Week 01 - 2012 700 600 500 400 300 kWh 200 100 0 Line 01 Line 02 Line 03 Line 04 Line 05 More meters: we can compare electricity usage between production lines. But we still can’t tell if Line 04 has run for a longer period.KEEPING INDUSTRY MOVING AND IMPROVING...
  12. 12. Even Better: Energy Consumption byAsset Line 01 - Assets, Week 01 - 2012 500 400 300 kWh 200 100 0 Filler Capper Boxmaker More meters: the filler has consumed the most electricity But we still don’t know how many products have been made.KEEPING INDUSTRY MOVING AND IMPROVING...
  13. 13. Full Picture: Energy and ProductProduced Base kWh load Performance blip Higher than base load, production has finished and staff forgot to turn off the glue unitKEEPING INDUSTRY MOVING AND IMPROVING...
  14. 14. Energy Usage with Drill down toAssetsKEEPING INDUSTRY MOVING AND IMPROVING...
  15. 15. Energy Usage Over Time with UnitsProducedKEEPING INDUSTRY MOVING AND IMPROVING...
  16. 16. Gathering the Data Pulse Meters for Gas & Water •OEE already provides: •Asset Structure •Running Hours •Products Made •Stoppage Events •Productivity •Utilisation Current •EnergyData feeds Transformers will provide: •Energy Consumed •Energy per Production unit by time •Energy usage comparisons: •Line / Shift / ProductKEEPING INDUSTRY MOVING AND IMPROVING...
  17. 17. Opportunities• Can we turn heaters on later?• Can we install more efficient heaters?• Can the plant run faster for the same energy usage?• Can any equipment be powered down during a breakdown or Production stoppage?• Can we automate power shutdown?• Can we use OEE analysis improve in these areas: • Minor stops • Slow running • Material scheduling failures • Quality issues • Line and machine downtime • ‘No Production Required’ windows KEEPING INDUSTRY MOVING AND IMPROVING...
  18. 18. ROI: BakeryReturn on Investment per Costsproduction line £ High volume OEE system 4,000 Internal manpower £ High waste allocation at start up 1,000 Low product unit price £ High energy cost Total 5,000 Significant quality monitoring Manual data capture Potential Savings per 1% Some opportunities for manpower Day Value now improvement reduction £ £ Product sales value 24,000 240 Daily throughput 80000 £ Sales revenue per unit 0.30 £ £ Cost of Waste 1,500 15 £ £ Manpower 2,500 25 £ £ Energy 7,000 70 £ £ Quality management 100 10 £ Total 360 KEEPING INDUSTRY MOVING AND IMPROVING... on Investment Return 14Days
  19. 19. ROI: Spirit Bottler Return on Investment Costs per line £ High volume OEE system 15,000 Internal manpower £ Low waste allocation 1,500 Moderate product unit price £ Steady energy usage Total 16,500 Automated quality monitoring Automated data capture with Potential Savings 1% manual input per Day Value now improvement Some opportunities for £ £ manpower reduction Product sales value 28,000 280 Daily throughput 7000 £ Sales revenue per unit 4.00 £ £ Cost of Waste - - £ £ Manpower - - £ £ Energy - - £ £ Quality management - - £ Total 280KEEPING INDUSTRY MOVING AND IMPROVING... on Return Investment 59 Days
  20. 20. ROI: Tractor FactoryReturn on Investment Costsfor the site OEE system £ 100,000 Low volume Internal manpower £ Low waste allocation 20,000 High product unit price £ Total 120,000 Steady energy usage Significant quality monitoring Automated data capture with Potential Savings 0.01% manual input per Day Value now improvement Few opportunities for £ £ manpower reduction Product sales value 12,000,000 12,000 Daily throughput 120 £ Sales revenue per unit 100,000 £ £ Cost of Waste - - £ £ Manpower - - £ £ Energy - - £ £ Quality management - - £ Total 12,000KEEPING INDUSTRY MOVING AND IMPROVING... on Return Investment 10Days
  21. 21. Summing Up• The drive to increase energy efficiency will continue• Better management of energy usage will be required• Better management will require better information• Good information is provided by more & higher quality data• Restrict energy usage to what is required to PRODUCE• OEE systems with Energy Monitoring will deliver the information requiredKEEPING INDUSTRY MOVING AND IMPROVING...

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