We all know that your factory’s greatest asset is its people. CDC Factory can help you unlock their potential by increasing productivity and paving the way for continuous improvement.

1. CDC Factory Overview
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2. What does CDC Factory do?
 Captures performance information in real time
– When the line stops / slows
– When scrap / rework is produced
 Presents information in Real time
– Visibility across all the lines
– Improving the communication
 Alerts
– Automatic alerts for unusual conditions
– Immediate reaction to issues
 Captures quality information in real time
– Operator checks
– Weight control checks
 Driving meeting structures (Huddles)
– Information to drive actions
 Defines a standard set of KPI’s (Key Performance Indicators)
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3. Sample Customers…..
P a pe r, B oa rd & F o o d & D r in k P h a r m a /F M C G
P r in t in g Kerry Foods Pfizer Adams
Kimberly-Clark Heinz Genentech
Knauf Geest PLC Smith & Nephew
Royal Bank of Scotland Greencore Kalon Decorative Products
SCA Hygiene Tetley tea Amtico
Bank of England printing works Coors Brewers Warwick International
Kappa Packaging Toms Confectionary Dupont Teijin
Glanbia
A u t o m o t iv e / Manor Bakeries P o w e r /U t i l i t i e s
C o mp o ne nts Scottish Courage ESBi
Toyota RHM Ingredients UKAEA
Corus Steel& Automotive Allied Bakeries Elyo Cofreth
Lotus Cars Calypso Soft drinks AEP Energy
Newage International Weetabix Associated British Ports
AGCO Wornick Foods
Caterpillar G e ne ra l
Trelleborg SITA Tyre Recycling
BMW - Body panels (for Rover) Foster Yeoman
INCO Refinery
Laporte Industries
Bio Products
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4. Typical Pains – Shop Floor
 Too much paperwork
 Constant & repetitive plant problems
 No-one does anything about issues raised
 No visibility of what’s happening up/downstream
 Unsure if on target for the shift
 Not sure of what to do in certain scenario’s
? ? ?
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5. Typical Pains – Supervisor
 Too much paperwork & Excel work
 Constant pressure to perform better
 Can’t prove where the problems are
 Don’t know why we keep missing targets
 No visibility of performance until after the event
 Difficult to make people accountable
? ?
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6. Performance Measurement & Management Challenges
Behavior Change
Root
Cause?
Best Practice Frequent
OEE 60%
Yield 96%
Operations Reviews
Cost / Unit $0.53
Management
Structured
Cont .Imp.
OEE 66%
Performance Change
Yield 98% Immediate
Cost / Unit $0.49 Unavoidable Action
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7. Shop Floor Interface: Real Time Inputs & Performance
Feedback, Management of Daily Operating Practices
!
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8. Typical Data captured on a line
 In order to capture performance, you don’t need dozens of signals
– The signals that will be used for each line have been identified and will be
explained during the training classes
Temperature REJECT Weight
IN count STATUS OUT Count
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9. Overall Equipment Effectiveness (OEE)
OEE is a measure of efficiency
– Always expressed as a percentage
It tells you how your cell/factory has performed over a given period (Production Run, Shift,
Specific time period)
OEE can be broken down into the 3 main elements;
– Rate (of Production whilst running)
– Yield (Scrap, rework, material loss)
– Utilization (Up-time Vs Downtime whilst scheduled to run)
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10. OEE - Definitions
Utilization
– Of the time that we planned to run the machine, what percentage of that time did it
actually run. (Uptime Vs Downtime). Some text books may also refer to this as
Availability.
Rate
– While the machine actually ran, at what percentage of the predetermined rate did the
machine actually run at. Some text books may also refer to this as Performance.
Yield
– What percentage of all the products produced were good products. Some text books
may also refer to this as Quality.
OEE
– Calculated by Multiplying the %Efficiency, by the %Rate, by the %Yield, giving an
Overall Equipment Effectiveness measure
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11. Uptime, Downtime and Slow Running Time
 Each minute, the system compares the “Rate” of production with
the ‘Planned Rate’ (for the current product)
 The ‘Status’ is usually based on a percentage of the Planned Rate
% of Planned Rate
Status of Plant
100%
Running (uptime)
70%
Slow Running (uptime)
10%
Stopped (downtime)
0%
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12. ‘Out-of-the-Box’ Infrastructure for a line
In We igh t O ut
Te m p S tatu s
C o u nt R e j ct
e C o u nt
OE E = Rate x Yield x Utilization
OEE
R ate Yie ld U til Rate = Units per min VS . s td rate
S LOW
S TOP
100%
100% 100% 100%
Produc t 97% Yield = Out / total proces s ed in
71%
1 00g S trawb e rry 93%
79% 89%
56%
C ount 71%
54%
52% Utilization = Uptime / Net A vail time
10
9
4
3
2
8
7
6
1 49%
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13. The Cell Page
 Key operator
interface
 Designed around
touch screen use
 Minimal typing
 Easy to use
 Real time OEE and
task alerting
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14. Logging a stoppage - Select the machine
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15. Logging a stoppage - select the reason
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16. Logging a stoppage - and that’s it!!
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17. Logging a Quality Check – Automatic alerting
 The system
will alert you
when a quality
check is due
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18. Logging a Quality Check – Entering the results
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19. Logging a Quality Check – Did it Pass or Fail?
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20. Weight Control Reporting
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21. End Of Shift Review
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22. Factory Dashboard
 Overview of all
lines
 Which line
requires focus
 Attainment to plan
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