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© FORCAM 2016 www.forcam.com 1
WHITE PAPER
www.forcam.com
We Deliver Results In
Productivity
Lead by TRUE OEE
Smart Factory Revolution FORCAM FORCETM
© FORCAM 2016 www.forcam.com 2
WHITE PAPER
Lead By True OEE
Shop Floor Management Principles
Planned vs Actual
CIP Organisation
Shop Floor Cockpit
Smart Factory
Innovations
About FORCAM
Success Stories
Contents
We Deliver Results In Productivity
FORCAM develops solutions and concepts for the Smart Factory. Recognized as the
pioneer of the “Industry 4”, we have the courage to create new technologies and
thereby define standards for the future. We help manufacturers to remain competitive
by achieving sustainable gains in productivity and optimize resource efficiency.
© FORCAM 2016 www.forcam.com 3
Manufacturing is getting more and more complex: Products can be individualised,
production cycles are shorter and global competition stronger than ever before.
To meet these rising demands a manufacturer needs to be as efficient and as
transparent as possible. Productivity is the crucial factor for staying competitive
and securing work places.
Manufacturing and the Internet will soon be inseparable.“
Apart from real-time visualisation, Shop Floor Management systems deliver
tangible, objective data from all production assets. In order to make
improvements on the shop floor, you need these data in the form of key
performance indicators (KPIs) to use as a benchmark. Also reviewing current cycle
times and targets makes sense. Users are often surprised by automated data, as
these can be considerably different from their expectations.
Reliable data and KPIs such as Overall Equipment Effectiveness are the first step.
But how can these be leveraged to reach higher productivity and make the
improvements necessary?
Lead by TRUE OEE
How can real-time data be used?
Where are the points for improvement?
How can OEE be used as a management tool?
© FORCAM 2016 www.forcam.com 4
2. Management Tool
ERP systems are not suited to support the CIP organization. Real time ERP data
combined with machine data is required to visualize the real status of the shop
floor and to calculate a TRUE OEE. Planned vs. Actual Performance Analysis is
the key element of Shop Floor Management.
1. Leadership Principle
Shop Floor Management is a top-down process. Management must be trained to
incorporate the CIP culture and to lead by OEE.
Shop Floor Management Principles as a Basis
for „True OEE“
Traditional Method Advanced Shop Floor
Management
OEE isn‘t used as KPI as
management tool.
No online visualisation.
Manual data collection
(Lean Dogma: Data collected by
machine operators)
Far from Reality
Management Style:
”Management by Remote Control“
Reliable, automated and objective
performance analysis.
Transparency through real-time
visualisation and all KPIs at a
glance.
Based on reality
Management Style:
”Management by Process Improvement“
M a n a g e m e n t
T o o l
L e a d e r s h i p
P r i n c i p l e
© FORCAM 2016 www.forcam.com 5
True OEE is driven by Planned vs. Actual performance
information collected in real time
The Lean Philosophy empowers the shop floor operator. The operator needs to
know what the supply chain (ERP) expects from him such as when to start an order/
operation and what target must be fulfilled. Planned vs. Actual performance
information in real time will give the operator immediate feedback about the
current performance of his manufacturing workplace in order to take immediate
measures in the case of a deviation from target.
How are you currently measuring shop floor performance?
Planned-Actual Comparison
Traditional Method Advanced Shop Floor
Management
R E A L - T I M E
R E L I A B L E
D A T A
M A N U A L
C O L L E C T I O N
Are there discrepancies between planned and actual set-up times?
Are there discrepancies between planned and actual cycle times?
How are you currently monitoring and tracking planned output and
what is acutally produced?
© FORCAM 2016 www.forcam.com 6
Your Recipe for Success - holistic Shop Floor Management that effectively combines the
most advanced Shop Floor Management System with the Lean Management philosophy.
Measuring TRUE OEE - what you cannot measure you cannot improve
Adopting Lean Management principles and leading by OEE
Creating a Continuous Improvement Process (CIP) culture with closed-loop
communication
Delivering the right information to right people at the right time
Delivering planned vs. actual performance information real-time to shop floor
operators
Establishing a PDCA (Plan-Do-Check-Act) cycle with actions and measures
Setting regular TRUE OEE goals for continuous improvement
Recipes for Success
Shop Floor Management
© FORCAM 2016 www.forcam.com 7
Advanced Shop Floor Management (SFM) technology must
support all organizational roles within the CIP Organization.
All manufacturing roles are supported by advanced shop floor management
technology with no exceptions, from the machine operator to maintenance to the
plant manager.
Continuous Improvement Process (CIP Organisation)
Foreman
Production Planning
Plant Manager
Overall Plant Performance
Maintenance
Hit lists
Drill-down analysis
Manufacturing Engineer
Production Data
Planned vs. Actual
Worker
Work Orders
Work Instructions
Machine
CIP Organisation
© FORCAM 2016 www.forcam.com 8
Periodic CIP Meetings, weekly and monthly, will utilize real time Shop
Floor data to monitor, analyze, and set goals and targets for:
Stoppages / Downtimes
Production Flow
Organization
Quality
Advanced Shop Floor Management (SFM) technology offers closed
loop CIP communication by delivering the right information to the
right role at the right time
CIP Communication
Tools Optimizations
Logistics
Worker Orders / Routing
Current Turnaround /
Productivity Values
© FORCAM 2016 www.forcam.com 9
Shop Floor Cockpit
Example at Audi Component Manufacturing
© FORCAM 2016 www.forcam.com 10
Cross-level OEE
OEE monitoring from machine-level, cell-level up to
cross-plant OEE monitoring.
<
Plant 2 Plant 3Plant 1
Cell 2Cell 1
Machine 1 Machine 2 Machine 3 Machine 4 Machine 5
Multi-
Plant
Plant
Hall
Cell
Group
Machine
72,0% 60,0% 70,0% 40,0% 55%
66,0% 55,0%
66,5% 49,5% 51,7%
60,5%
60,5%
66,0%
© FORCAM 2016 www.forcam.com 11
World Class Shop Floor Management
Create A Transparent Factory
Planning and Production are now synchronized
“Today, companies need resource efficiency
in processes and in manufacturing “,
Franz Gruber, CEO FORCAM
Everything has to intertwine in a way that errors and waste can be recognized
immediately and eliminated sustainably.
The FORCAM technology complements standard ERP-software on the planning level
(top floor) using objective performance data coming directly from all factory assets
(shop floor) – from one single machine to multiple plants worldwide. The efficiency
factor of standard ERP-software is enhanced due to the real-time data capture by
FORCAM.
The SMART FACTORY Starter Kit is a way to test Industry 4.0 technologies.
Deployment is fast, cheap and risk-free, and can deliver increased machine
availability by 10% in the 3 month test period.
SMART FACTORY
Measuring and optimizing the performance of
manufacturing plants anywhere, anytime
The real-time information provided by FORCAM
can be accessed through mobile gadgets
including smartphones and tablets.
© FORCAM 2016 www.forcam.com 12
State-Of-The-Art Shop Floor Management
Flexible web-based connectivity of a diverse number of machine controls
FORCAM‘s Factory Framework™ solution is technologically leading Manufacturing
Execution System (MES). It enables improvement processes on all levels of the
production. Factory Framework™ connects, collects, and standardizes real-time data
from most different machine controls. For every production level, the signals
provide comparable web-based operational states of machines and plants
(production, malfunctions, and downtimes).
Innovations
© FORCAM 2016 www.forcam.com 13
State-Of-The-Art Shop Floor Management
Innovations
Results: Fast reaction with latencies in the millisecond range and high throughput.
Rule-based approach enables flexible, user-defined functions. Global deployment
potential with Unicode language support and centralized server architecture
© FORCAM 2016 www.forcam.com 14
Overall Equipment Effectiveness (OEE)
Shop Floor Management (SFM) is a strategy designed for the continuous
optimization of the plant availability by eliminating errors and waste. The most
important key figure to measure the performance is the OEE – Overall Equipment
Effectiveness.
As key performance indicator, OEE
is the result of three factors:
o Availability
o Performance
o Quality
OEE is the most important figure (KPI) to
implement the shop floor management strategy.
Increasing the OEE can help speed up the ROI on
your Shop Floor Management system and even
your production assets.
OEE - Three crucial performance metrics: Availability,
Productivity, Quality
SFM Technology
© FORCAM 2016 www.forcam.com 15
MARKET Discrete Manufacturing Industries
PRODUCT Shop Floor Management (& Consulting)
TECHNOLOGY FORCAM FORCETM
CUSTOMERS (amongst others) Audi, BMW, Daimler, BorgWarner, MTU
Aero Engines, Hilti, Mann+Hummel, WEIR Minerals
BENEFITS > Significant improvements in productivity (up to 20%)
> Accelerated Return on Investment (ROI 1 Year)
> Optimized Return on Capital Employed (ROCE)
> Improved transparency leading to lower costs
> Higher energy and resource efficiency
MANAGEMENT Former SAP Manager founded FORCAM in 2001.
Strategic investor Dietmar Hopp
Offices > Ravensburg, Germany (HQ)
> Switzerland
> England
> USA
> China
> Poland
With FORCAM customers regularly achieve increases in
productivity in terms of OEE of 20% or more
FORCAM at a Glance
© FORCAM 2016 www.forcam.com 16
o Factory of the Year 2007, 2008, 2012 und 2013 (by A.T. Kearney)
o Delivering monitoring and optimization of more than 14,000 machine tools
o Audi Stamping Plants + 20% increase in TRUE OEE within 12 months
o Audi Components Plants + 10% increase in TRUE OEE within 12 months
o
o Exceeding expectations with unique shop floor management strategy
o 4.3% increase in TRUE OEE within 6 months
o 12% increase in TRUE OEE within 6 months
With FORCAM technology, elite companies have increased productivity
by up to 20% within the first year, measured by TRUE Overall Equipment
Effectiveness (OEE).
Success Stories
© FORCAM 2016 www.forcam.com 17
FORCAMEU
FORCAM GmbH (HQ)
An der Bleicherei 15
88214 Ravensburg
Tel.: +49 751/366 69 0
info@forcam.com
FORCAM Ltd
Lumonics House
Valley Drive, Rugby
CV21 1TQ, United Kingdom
info@forcam.com
Phone +44 (0)1788 247123
250 E. Fifth Street, 15th Floor
Cincinnati,
OH 45202, USA
info@forcam.com
Phone HQ +1 (513) 878-2780
您想联系我们?
富勘(上海)软件技术有限公司
陆家嘴东路161号2613室
上海市浦东新区
邮编 200120, 中国
china@forcam.com
电话 +86 21 6869 0126
FORCAMUK
FORCAMUS FORCAMCN
© FORCAM 2016 www.forcam.com 18
COPYRIGHT 2016 BY FORCAM GMBH
D-88214 Ravensburg
ALLE RECHTE VORBEHALTEN. NACHDRUCK ODER ÜBERSETZUNG, AUCH
AUSZUGSWEISE NUR MIT SCHRIFTLICHER GENEHMIGUNG DER FORCAM GMBH
If you cannot
measure it,
you cannot
improve it
Lord Kelvin
FORCAM GmbH
An der Bleicherei 15
88214 Ravensburg
Telefon: +49 751 36669-0
Fax: +49 751 36669-88
info@forcam.com

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FORCAM White Paper (2016) - Lead by TRUE OEE

  • 1. © FORCAM 2016 www.forcam.com 1 WHITE PAPER www.forcam.com We Deliver Results In Productivity Lead by TRUE OEE Smart Factory Revolution FORCAM FORCETM
  • 2. © FORCAM 2016 www.forcam.com 2 WHITE PAPER Lead By True OEE Shop Floor Management Principles Planned vs Actual CIP Organisation Shop Floor Cockpit Smart Factory Innovations About FORCAM Success Stories Contents We Deliver Results In Productivity FORCAM develops solutions and concepts for the Smart Factory. Recognized as the pioneer of the “Industry 4”, we have the courage to create new technologies and thereby define standards for the future. We help manufacturers to remain competitive by achieving sustainable gains in productivity and optimize resource efficiency.
  • 3. © FORCAM 2016 www.forcam.com 3 Manufacturing is getting more and more complex: Products can be individualised, production cycles are shorter and global competition stronger than ever before. To meet these rising demands a manufacturer needs to be as efficient and as transparent as possible. Productivity is the crucial factor for staying competitive and securing work places. Manufacturing and the Internet will soon be inseparable.“ Apart from real-time visualisation, Shop Floor Management systems deliver tangible, objective data from all production assets. In order to make improvements on the shop floor, you need these data in the form of key performance indicators (KPIs) to use as a benchmark. Also reviewing current cycle times and targets makes sense. Users are often surprised by automated data, as these can be considerably different from their expectations. Reliable data and KPIs such as Overall Equipment Effectiveness are the first step. But how can these be leveraged to reach higher productivity and make the improvements necessary? Lead by TRUE OEE How can real-time data be used? Where are the points for improvement? How can OEE be used as a management tool?
  • 4. © FORCAM 2016 www.forcam.com 4 2. Management Tool ERP systems are not suited to support the CIP organization. Real time ERP data combined with machine data is required to visualize the real status of the shop floor and to calculate a TRUE OEE. Planned vs. Actual Performance Analysis is the key element of Shop Floor Management. 1. Leadership Principle Shop Floor Management is a top-down process. Management must be trained to incorporate the CIP culture and to lead by OEE. Shop Floor Management Principles as a Basis for „True OEE“ Traditional Method Advanced Shop Floor Management OEE isn‘t used as KPI as management tool. No online visualisation. Manual data collection (Lean Dogma: Data collected by machine operators) Far from Reality Management Style: ”Management by Remote Control“ Reliable, automated and objective performance analysis. Transparency through real-time visualisation and all KPIs at a glance. Based on reality Management Style: ”Management by Process Improvement“ M a n a g e m e n t T o o l L e a d e r s h i p P r i n c i p l e
  • 5. © FORCAM 2016 www.forcam.com 5 True OEE is driven by Planned vs. Actual performance information collected in real time The Lean Philosophy empowers the shop floor operator. The operator needs to know what the supply chain (ERP) expects from him such as when to start an order/ operation and what target must be fulfilled. Planned vs. Actual performance information in real time will give the operator immediate feedback about the current performance of his manufacturing workplace in order to take immediate measures in the case of a deviation from target. How are you currently measuring shop floor performance? Planned-Actual Comparison Traditional Method Advanced Shop Floor Management R E A L - T I M E R E L I A B L E D A T A M A N U A L C O L L E C T I O N Are there discrepancies between planned and actual set-up times? Are there discrepancies between planned and actual cycle times? How are you currently monitoring and tracking planned output and what is acutally produced?
  • 6. © FORCAM 2016 www.forcam.com 6 Your Recipe for Success - holistic Shop Floor Management that effectively combines the most advanced Shop Floor Management System with the Lean Management philosophy. Measuring TRUE OEE - what you cannot measure you cannot improve Adopting Lean Management principles and leading by OEE Creating a Continuous Improvement Process (CIP) culture with closed-loop communication Delivering the right information to right people at the right time Delivering planned vs. actual performance information real-time to shop floor operators Establishing a PDCA (Plan-Do-Check-Act) cycle with actions and measures Setting regular TRUE OEE goals for continuous improvement Recipes for Success Shop Floor Management
  • 7. © FORCAM 2016 www.forcam.com 7 Advanced Shop Floor Management (SFM) technology must support all organizational roles within the CIP Organization. All manufacturing roles are supported by advanced shop floor management technology with no exceptions, from the machine operator to maintenance to the plant manager. Continuous Improvement Process (CIP Organisation) Foreman Production Planning Plant Manager Overall Plant Performance Maintenance Hit lists Drill-down analysis Manufacturing Engineer Production Data Planned vs. Actual Worker Work Orders Work Instructions Machine CIP Organisation
  • 8. © FORCAM 2016 www.forcam.com 8 Periodic CIP Meetings, weekly and monthly, will utilize real time Shop Floor data to monitor, analyze, and set goals and targets for: Stoppages / Downtimes Production Flow Organization Quality Advanced Shop Floor Management (SFM) technology offers closed loop CIP communication by delivering the right information to the right role at the right time CIP Communication Tools Optimizations Logistics Worker Orders / Routing Current Turnaround / Productivity Values
  • 9. © FORCAM 2016 www.forcam.com 9 Shop Floor Cockpit Example at Audi Component Manufacturing
  • 10. © FORCAM 2016 www.forcam.com 10 Cross-level OEE OEE monitoring from machine-level, cell-level up to cross-plant OEE monitoring. < Plant 2 Plant 3Plant 1 Cell 2Cell 1 Machine 1 Machine 2 Machine 3 Machine 4 Machine 5 Multi- Plant Plant Hall Cell Group Machine 72,0% 60,0% 70,0% 40,0% 55% 66,0% 55,0% 66,5% 49,5% 51,7% 60,5% 60,5% 66,0%
  • 11. © FORCAM 2016 www.forcam.com 11 World Class Shop Floor Management Create A Transparent Factory Planning and Production are now synchronized “Today, companies need resource efficiency in processes and in manufacturing “, Franz Gruber, CEO FORCAM Everything has to intertwine in a way that errors and waste can be recognized immediately and eliminated sustainably. The FORCAM technology complements standard ERP-software on the planning level (top floor) using objective performance data coming directly from all factory assets (shop floor) – from one single machine to multiple plants worldwide. The efficiency factor of standard ERP-software is enhanced due to the real-time data capture by FORCAM. The SMART FACTORY Starter Kit is a way to test Industry 4.0 technologies. Deployment is fast, cheap and risk-free, and can deliver increased machine availability by 10% in the 3 month test period. SMART FACTORY Measuring and optimizing the performance of manufacturing plants anywhere, anytime The real-time information provided by FORCAM can be accessed through mobile gadgets including smartphones and tablets.
  • 12. © FORCAM 2016 www.forcam.com 12 State-Of-The-Art Shop Floor Management Flexible web-based connectivity of a diverse number of machine controls FORCAM‘s Factory Framework™ solution is technologically leading Manufacturing Execution System (MES). It enables improvement processes on all levels of the production. Factory Framework™ connects, collects, and standardizes real-time data from most different machine controls. For every production level, the signals provide comparable web-based operational states of machines and plants (production, malfunctions, and downtimes). Innovations
  • 13. © FORCAM 2016 www.forcam.com 13 State-Of-The-Art Shop Floor Management Innovations Results: Fast reaction with latencies in the millisecond range and high throughput. Rule-based approach enables flexible, user-defined functions. Global deployment potential with Unicode language support and centralized server architecture
  • 14. © FORCAM 2016 www.forcam.com 14 Overall Equipment Effectiveness (OEE) Shop Floor Management (SFM) is a strategy designed for the continuous optimization of the plant availability by eliminating errors and waste. The most important key figure to measure the performance is the OEE – Overall Equipment Effectiveness. As key performance indicator, OEE is the result of three factors: o Availability o Performance o Quality OEE is the most important figure (KPI) to implement the shop floor management strategy. Increasing the OEE can help speed up the ROI on your Shop Floor Management system and even your production assets. OEE - Three crucial performance metrics: Availability, Productivity, Quality SFM Technology
  • 15. © FORCAM 2016 www.forcam.com 15 MARKET Discrete Manufacturing Industries PRODUCT Shop Floor Management (& Consulting) TECHNOLOGY FORCAM FORCETM CUSTOMERS (amongst others) Audi, BMW, Daimler, BorgWarner, MTU Aero Engines, Hilti, Mann+Hummel, WEIR Minerals BENEFITS > Significant improvements in productivity (up to 20%) > Accelerated Return on Investment (ROI 1 Year) > Optimized Return on Capital Employed (ROCE) > Improved transparency leading to lower costs > Higher energy and resource efficiency MANAGEMENT Former SAP Manager founded FORCAM in 2001. Strategic investor Dietmar Hopp Offices > Ravensburg, Germany (HQ) > Switzerland > England > USA > China > Poland With FORCAM customers regularly achieve increases in productivity in terms of OEE of 20% or more FORCAM at a Glance
  • 16. © FORCAM 2016 www.forcam.com 16 o Factory of the Year 2007, 2008, 2012 und 2013 (by A.T. Kearney) o Delivering monitoring and optimization of more than 14,000 machine tools o Audi Stamping Plants + 20% increase in TRUE OEE within 12 months o Audi Components Plants + 10% increase in TRUE OEE within 12 months o o Exceeding expectations with unique shop floor management strategy o 4.3% increase in TRUE OEE within 6 months o 12% increase in TRUE OEE within 6 months With FORCAM technology, elite companies have increased productivity by up to 20% within the first year, measured by TRUE Overall Equipment Effectiveness (OEE). Success Stories
  • 17. © FORCAM 2016 www.forcam.com 17 FORCAMEU FORCAM GmbH (HQ) An der Bleicherei 15 88214 Ravensburg Tel.: +49 751/366 69 0 info@forcam.com FORCAM Ltd Lumonics House Valley Drive, Rugby CV21 1TQ, United Kingdom info@forcam.com Phone +44 (0)1788 247123 250 E. Fifth Street, 15th Floor Cincinnati, OH 45202, USA info@forcam.com Phone HQ +1 (513) 878-2780 您想联系我们? 富勘(上海)软件技术有限公司 陆家嘴东路161号2613室 上海市浦东新区 邮编 200120, 中国 china@forcam.com 电话 +86 21 6869 0126 FORCAMUK FORCAMUS FORCAMCN
  • 18. © FORCAM 2016 www.forcam.com 18 COPYRIGHT 2016 BY FORCAM GMBH D-88214 Ravensburg ALLE RECHTE VORBEHALTEN. NACHDRUCK ODER ÜBERSETZUNG, AUCH AUSZUGSWEISE NUR MIT SCHRIFTLICHER GENEHMIGUNG DER FORCAM GMBH If you cannot measure it, you cannot improve it Lord Kelvin FORCAM GmbH An der Bleicherei 15 88214 Ravensburg Telefon: +49 751 36669-0 Fax: +49 751 36669-88 info@forcam.com