Stephen Mummery Matthews Presentation
The Manufacturing Journey into Lean & OEE June 2012
Our Business •
Australian and family owned
•
Over 35+ years in Australia
•
Strategic Alliance Partners with GS1 Australia
•
Sales and Service around the nation ( VIC Head Office)
•
Core business has always been product identification but we have evolved as industry and clients has required us to……
•
Hence our journey into Lean and OEE….
Product Identification requirements • Primary, secondary and tertiary identification for product traceability through the supply chain
Packaging Floor Issues • Inefficient code management practices • Coding errors: rework, wastage or recall • Multiple platforms: different interfaces, multiple messages, multiple
Production floor:
operators • SSCC Label printing separate process • No central point of control • Poor in-line quality control
• Increasing requirements for product trace-ability • Lack of overall plant visibility
Production Office:
• Poor connectivity from plant up to MRP/ERP systems • Poor automated production reporting • Poor automated fault reporting
Lean and OEE requirements
OEE is a global best practice measure to monitor and improve the effectiveness of manufacturing processes
“You cannot manage what you cannot measure."Bill Hewlett, Co-founder of Hewlett-Packard
Industry perspective
“Improve productivity and efficiency or perish” Terry O’Brien Managing Director
Why the drive for Lean and OEE in industry Lean practices focus on reduction of non- value adding waste in manufacturing Production waste includes: •
Waiting times
•
Overproduction
•
Rework
•
Motion times
Why OEE? OEE = Availability x Performance x Quality Availability = Uptime of equipment Actual running time/Planned running time Performance = Machine production Actual production/Potential production Quality = finished product Good units/Produced units
Lean systems The pillars of Lean include: Metrics, KPI’s and Score boarding Flexibility Perfecting quality Standardisation Continuous improvement
Effective combination of Lean and OEE Lean practices + strong OEE means: Productive manufacturing Efficient production Profitable products and businesses
OEE requirements Reporting
“….operations management can use mobile applications or software remotely to gain critical insights into their production processes, perform inspection and maintenance tasks, receive productivity and logistics reports” Manufacturers Monthly June 2012
OEE requirements Measurement
OEE requirements – Quality focus Visibility
OEE requirements Integration into ERP, MRP and SCADA systems
Packaging hall innovations Increased Production Efficiencies Packaging Management Software • Automation of coding • Dashboards & Scoreboards for real‐time monitoring of performance, availability and quality • Real time data on line status
Eliminate Coding & Labelling Errors
Packaging Management Software + Vision Inspection
• Central product database • Scan & download product changeovers • Machine vision inspection validation
Packaging Management Software
Vision inspection systems Application of camera and computer technologies to provide automatic inspection, process control and robot guidance in manufacturing and industrial applications.
Application – Cap position
Application
Application – Carton fill
Application – Label inspection
Vision Inspection – Quality focus •
•
Avoid any non shelf-ready product from reaching a customer •
Code presence & formation
•
Correct front & back label, crooked label
•
Cap color, cocked cap, tamper
•
Fill level
•
Damaged primary pack
Vision inspection provides the quality metrics for OEE –
Count of rejects
–
Reason for rejects
–
Any logic for redirecting rejects
Commercial in Confidence
A fine balance……
Quality Control
Quality Assurance
Systems integration outcomes Reduce waste, maintain OEE and deliver higher production levels but importantly have visible and instant reporting
Up-stream issues can be fixed in real-time
Alarms when the reject rate goes above the normal tolerance
Vision integrated with intelligent software that tracks defect rates in real time
Questions
Our Business •
Australian and family owned
•
Over 35+ years in Australia
•
Strategic Alliance Partners with GS1 Australia
•
Sales and Service around the nation ( VIC Head Office)
•
Core business has always been product identification but we have evolved as industry and clients has required us to……
•
Hence our journey into Lean and OEE….
Product Identification requirements • Primary, secondary and tertiary identification for product traceability through the supply chain
Packaging Floor Issues • Inefficient code management practices • Coding errors: rework, wastage or recall • Multiple platforms: different interfaces, multiple messages, multiple
Production floor:
operators • SSCC Label printing separate process • No central point of control • Poor in-line quality control
• Increasing requirements for product trace-ability • Lack of overall plant visibility
Production Office:
• Poor connectivity from plant up to MRP/ERP systems • Poor automated production reporting • Poor automated fault reporting
Lean and OEE requirements
OEE is a global best practice measure to monitor and improve the effectiveness of manufacturing processes
“You cannot manage what you cannot measure."Bill Hewlett, Co-founder of Hewlett-Packard
Industry perspective
“Improve productivity and efficiency or perish” Terry O’Brien Managing Director
Why the drive for Lean and OEE in industry Lean practices focus on reduction of non- value adding waste in manufacturing Production waste includes: •
Waiting times
•
Overproduction
•
Rework
•
Motion times
Why OEE? OEE = Availability x Performance x Quality Availability = Uptime of equipment Actual running time/Planned running time Performance = Machine production Actual production/Potential production Quality = finished product Good units/Produced units
Lean systems The pillars of Lean include: Metrics, KPI’s and Score boarding Flexibility Perfecting quality Standardisation Continuous improvement
Effective combination of Lean and OEE Lean practices + strong OEE means: Productive manufacturing Efficient production Profitable products and businesses
OEE requirements Reporting
“….operations management can use mobile applications or software remotely to gain critical insights into their production processes, perform inspection and maintenance tasks, receive productivity and logistics reports” Manufacturers Monthly June 2012
OEE requirements Measurement
OEE requirements – Quality focus Visibility
OEE requirements Integration into ERP, MRP and SCADA systems
Packaging hall innovations Increased Production Efficiencies Packaging Management Software • Automation of coding • Dashboards & Scoreboards for real‐time monitoring of performance, availability and quality • Real time data on line status
Eliminate Coding & Labelling Errors
Packaging Management Software + Vision Inspection
• Central product database • Scan & download product changeovers • Machine vision inspection validation
Packaging Management Software
Vision inspection systems Application of camera and computer technologies to provide automatic inspection, process control and robot guidance in manufacturing and industrial applications.
Application – Cap position
Application
Application – Carton fill
Application – Label inspection
Vision Inspection – Quality focus •
•
Avoid any non shelf-ready product from reaching a customer •
Code presence & formation
•
Correct front & back label, crooked label
•
Cap color, cocked cap, tamper
•
Fill level
•
Damaged primary pack
Vision inspection provides the quality metrics for OEE –
Count of rejects
–
Reason for rejects
–
Any logic for redirecting rejects
Commercial in Confidence
A fine balance……
Quality Control
Quality Assurance
Systems integration outcomes Reduce waste, maintain OEE and deliver higher production levels but importantly have visible and instant reporting
Up-stream issues can be fixed in real-time
Alarms when the reject rate goes above the normal tolerance
Vision integrated with intelligent software that tracks defect rates in real time
Questions
