PP New Design
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This document summarizes printing machine utilization and productivity metrics for 9 machines over a 26 day period. It provides data on the number of setups (make readies), total printed sheets, productivity, downtime reasons and hours. The Rotoman machine had the highest utilization at 94% and printed over 10 million sheets with 6% waste. The Roland500 had the lowest productivity at 30% utilization, printing under 200,000 sheets with 6% waste. Overall, the document analyzes printing machine performance statistics.
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PP New Design
- 2. Commercial printing Machines Utilization, No. of make ready, Total printed sheets and Productivity Working Hours and Downtime Details Effective speed related to the target and Waste percentage
- 3. 94% 86% 76% 69% 58% 71% 62% 30% 64% Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 Utilization 10,027,309 8,771,916 1,202,640 764,538 530,077 804953 568,979 181,946 563,552 Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 Total printed sheets 334 174 332 231 232 262 207 121 308 Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 No. of make ready 78% 88% 86% 68% 65% 76% 62% 38% 51% Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 Productivity
- 4. 4 55 Un planned MR Un planned RT 284 68% 59 14% 46 11% 27 7% Expected Downtime No Work HoursProduction CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Production Time = (Make ready + Running Time) Unplanned Down Time 343 83% 46 11% 27 6% Achieved 0.0 2.3 5.3 0.0 0.0 0.0 14.0 11.1 1.0 8.5 2.3 0.0 0.0 0.0 1.3 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Machine Rotoman Utilization 94% Availability 62% Productivity 78% Quality 94% OEE 45% No.of MR 334 no. of Sheets 10,027,309 Achieved Speed 39,192 PT achieved 343 Avearge Speed 50000 PT expected 284 Un planned DT 59 Unutilized time 27 Waste % 6%
- 5. 263 63% 64 15% 33 8% 56 14% Expected -2 65 Un planned MR Un planned RT KBA215 326, 78% 33, 8% 56, 14% Achieved 0.0 9.4 0.0 0.0 0.0 1.0 5.4 2.9 0.0 9.5 1.0 0.0 0.0 0.0 4.0 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine KBA215 Utilization 86% Availability 68% Productivity 88% Quality 95% OEE 57% No.of MR 174 no. of Sheets 8,771,916 Achieved Speed 30,815 PT achieved 326 Avearge Speed 40000 PT expected 263 Un planned DT 64 Unutilized time 56 Waste % 5% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 6. -12 -24 Un planned MR Un planned RT Kom8col 2 247 67% 69 19% 50 14% Achieved 5.5 34.0 6.0 0.0 0.0 0.5 0.0 5.5 2.0 6.0 0.0 2.1 0.0 0.0 5.6 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC… Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine Kom8col 2 Utilization 76% Availability 42% Productivity 86% Quality 97% OEE 35% No.of MR 332 no. of Sheets 1,202,640 Achieved Speed 6,843 PT achieved 247 Avearge Speed 8000 PT expected 233 Un planned DT 14 Unutilized time 100 Waste % 3% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) 283 65% -36 -8% 69 16% 50 11% Expected Downtime No Work HoursProduction Unplanned Down Time
- 7. 250 64% -45 -10% 84 21% 13 3% Expected 8 -80 Un planned MR Un planned RT Kom8col 1 205 68% 84 28% 13 4% Achieved 0.7 9.1 0.0 0.0 0.0 0.0 0.0 0.7 0.0 3.1 8.0 0.2 0.0 0.0 1.0 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine Kom8col 1 Utilization 69% Availability 34% Productivity 68% Quality 97% OEE 22% No.of MR 231 no. of Sheets 764,538 Achieved Speed 5,473 PT achieved 205 Avearge Speed 8000 PT expected 153 Un planned DT 52 Unutilized time 127 Waste % 3% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 8. 267 61% -85 -19% 59 14% 25 6% Expected 4 10 Un planned MR Un planned RT Kom4col 183 69% 59 22% 25 9% Achieved 3.9 24.8 5.0 0.0 0.0 1.5 0.0 3.9 0.0 0.0 0.0 18.0 0.0 0.0 1.8 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine Kom4col Utilization 58% Availability 24% Productivity 65% Quality 92% OEE 14% No.of MR 232 no. of Sheets 150,015 Achieved Speed 5,230 PT achieved 183 Avearge Speed 8000 PT expected 144 Un planned DT 39 Unutilized time 175 Waste % 8% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 9. 289 74% -42 -11% 46 12% 14 3% Expected 6 40 Un planned MR Un planned RT KBA105 4.4 21.8 5.5 0.0 0.0 2.5 0.0 4.4 0.0 0.8 0.0 2.6 0.0 0.0 3.9 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… 248 81% 46 15% 14 4% Achieved Production Time = (Make ready + Running Time) Machine KBA105 Utilization 71% Availability 32% Productivity 76% Quality 96% OEE 23% No.of MR 262 no. of Sheets 804,953 Achieved Speed 6,103 PT achieved 248 Avearge Speed 8000 PT expected 210 Un planned DT 38 Unutilized time 123 Waste % 4% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 10. 262 57% -86 -19% 83 18% 26 6% Expected -1 -10 Un planned MR Un planned RT KBA74 176 62% 83 29% 26 9% Achieved 3.5 27.3 15.5 3.8 0.0 2.3 0.0 3.5 0.0 4.0 0.0 19.7 0.0 0.0 3.8 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine KBA74 Utilization 62% Availability 28% Productivity 62% Quality 94% OEE 16% No.of MR 207 no. of Sheets 568,979 Achieved Speed 4,969 PT achieved 176 Avearge Speed 8000 PT expected 133 Un planned DT 43 Unutilized time 157 Waste % 6% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 11. 241 54%-144 -32% 29 6% 35 8% Expected 0 -25 Un planned MR Un planned RT Roland500 97 60% 29 18% 35 22% Achieved 2.0 11.2 3.0 0.0 0.4 0.0 0.0 2.0 0.3 0.0 0.0 9.4 0.0 0.0 0.0 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC Checking Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine Roland500 Utilization 30% Availability 15% Productivity 38% Quality 94% OEE 5% No.of MR 121 no. of Sheets 181,946 Achieved Speed 3,006 PT achieved 97 Avearge Speed 8000 PT expected 59 Un planned DT 38 Unutilized time 290 Waste % 6% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 12. 247 70% -34 -11% 51 15% 20 6% Expected -1 -20 Un planned MR Un planned RT SM52 213 75% 51 18% 20 7%Achieved 5.1 31.9 0.0 0.0 0.0 0.0 0.0 5.1 0.0 0.0 0.0 9.2 0.0 0.0 0.0 pallets change Blanket cleaning collecting paper… Waiting paper for… Waiting for helpers Waiting for plates Remake plates Waiting QC… Going to … Mechanical Electrical Wating ink for dry Filling report Make Ready Time Others production… Production Time = (Make ready + Running Time) Machine SM52 Utilization 64% Availability 33% Productivity 51% Quality 95% OEE 16% No.of MR 308 no. of Sheets 563,552 Achieved Speed 4,099 PT achieved 213 Avearge Speed 8000 PT expected 147 Un planned DT 66 Unutilized time 151 Waste % 5% CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS) Downtime No Work HoursProduction Unplanned Down Time
- 13. 334 174 332 231 232 262 207 121 308 Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 No. of make ready 6% 5% 3% 3% 8% 4% 6% 6% 5% Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 Waste % 39,192 30,815 6,843 5,473 5,230 6,103 4,969 3,006 4,099 50,000 35,000 8,000 8,000 8,000 8,000 8,000 8,000 8,000 65,000 45,000 16,000 16,000 16,000 18,000 16,000 18,000 16,000 Rotoman KBA215 Kom8col2 Kom8col1 Kom4col KBA105 KBA74 Roland500 SM52 Effective Avarge Speed Actual speed CALCULATION IS BASED ON 416 HOURS (26 DAYS X 2 SHIFTS X 8 HOURS)
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