Improving Asset Utilization The Key to World Class ManufacturingPROPRIETARY NOTICEThe information contained on all pages of this document consists of technical, commercial, and / or financial information which isconfidential and proprietary to Woodard & Curran. This information is presented in confidence to our Customer with the understanding thatit may not be reproduced or used, in whole or in part, for any purpose other than evaluation of the services described herein.
Our Objective Assist client in their path toward a more competitive, world-class, efficiency- driven, agile & growth-oriented supply chain network Woodard & Curran values this beverage client as a major strategic client. We want to be the consultant of choice in engineering services.
Focus on Manufacturing Performance Methodology Parameters: – Measures effectiveness of an asset – Based on industry standards to compare & benchmark base line metrics – Repeatable and consistent – Flexible and scalable – Based upon an open technology Metric to be used is: Overall Equipment Effectiveness (OEE)
How is OEE derived? Time Example Time Lost Causes Key Performance Indicators Overall Equipment Effectiveness == Overall Equipment Effectiveness Single Shift Single Shift Availability xxPerformance xxQuality OEE Factor World Class(PE) x Quality Availability Performance (EA) (EA) xx (PE) x (QR)(QR) Lunch Breaks Stops Lunch Breaks Stops Available Time Available Time Availability Meetings 90.0% Meetings Performance Equipment Failure 95.0% Down Availability ==Available Time ––Down Time Time Equipment Failure Down Run Time Availability Available Time Down Time Time Run Time Available Time Setup & Adjustment Available Time Quality & Adjustment Setup 99.9% Losses Reduced Speed Speed Performance == Production Losses Reduced Speed Speed Full Capacity Overall OEE Stops Performance 90.0% Production Full Capacity Idling & Minor 90.0% Rated Speed xxRun Time Rated Speed Run Time Idling & Minor Stops Rejects Good Rejects Rejects Good Rejects Quality ==Production -Rejects Quality Production -RejectsProduction Production Production Reduced Yield Reduced Yield Production
What is the program Woodard & Curran proposes??? Analyze Measure OEE equipment data Implement solution
Phase 1: Measure Evaluate/upgrade line communication architecture Map data in OEM control processors Install data server and concentrator Install KPI software Then … collect data for three months
Quick road to the benefitsPackaged KPI application?… Decreased time-to-deployment – Accelerates payback and ROI Reduced project risk and cost – Well defined scope – Proven, pre-packaged application functionality – Based on extensive domain expertise, knowledge of market best practices, and operational/business processes Sustainability of solution – Packaged software upgraded periodically to stop technology stagnation
Phase 1: Deliverables Factory Metrics installed on two lines Facility controls architecture upgraded and documented Listing of data tables in OEM equipment
Phase 2: AnalyzePerformance affected by: – Line design – Equipment reliability – Equipment integration – Packaging material suppliers – Operator training – Plant culture and management
Phase 2: Deliverables Recommendations for improvement Prioritize problems to tackle Contractual options for W&C to implement solutions with possible performance guarantee
Phase 3: Implement Procure equipment and contractors as needed Schedule upgrades on plant equipment Implement additional training as needed The key to success… our Partners in Change
The Change Management Team Woodard & Curran Program Manager OrganizationW&C Engineers KPI Software Supplier OEMs Material Suppliers Training Consultants Controls Design Primary Packaging Equipment Programmers Secondary Packaging Equipment Packaging Engineers
Next Steps Client selects two target sites Preliminary Engineering Proposal – Evaluate controls architecture – Analyze OEM processor data structure Phase 1 and 2: Measure and Analyze – Implement necessary control upgrades – Install Factory Metrics – Collect data and issue report Phase 3: Implement – Implement corrective action