More output, more profit. As simple as the formula may sound, the driving factors are difficult to identify. The PROXIA OEE / CIP method based on operational data acquisition enhanced by messenger services and PROXIA action management shows where the potential can really be found on the shop floor.
OEE (Overall Equipment Effectiveness) is the key figure in production that all eyes are on. Put simply, OEE is the product of availability, performance and quality of a machine network. However, the contributions to OEE - typically at values between 75% and 100% - have different influence. Especially when it comes to tirelessly increasing the OEE in the spirit of MES and Kaizen.
If you take a look at the detailed key figures that make up the OEE:
Quality: A dedicated quality management system has been in place in many manufacturing companies for many years, with the nice result that the relative values for quality are already close to the 100 percent mark (grade 1.0). Significant improvements are therefore not to be expected here.
The performance: Without a doubt, the performance is an essential parameter of large-scale manufacturers, but it offers few starting points for classic mechanical engineering and special machine construction with their manageable quantities. Because the performance of the machines essentially determines the performance, and this is due to the technology. So a milling machine with a certain cutting performance was deliberately bought.
Availability: It remains the driving force when we consider performance and quality as described above. The availability of the machines is the central element in optimizing the OEE. Based on the assumption that quality and performance in relation to availability show only a very small variance, an increased system availability is the key to an improved OEE. Therefore, the PROXIA OEE / CIP method focuses particularly on availability.
PROXIA has now brought an action manager onto the market in order to validate and verify the results reliably as part of a continuous improvement process (CIP). With the PROXIA Action Manager, the user can track down precisely those contributions that have thwarted the 100 percent goal of availability so far.
Background: The ERP system is only interested in the “green area” of availability (“machine on the move”), because this information is relevant for calculation. Red, however, stands for all the "unproductive" times such as breaks, setting up, no staff, no material or crane is missing. However, these times cannot initially be charged to anyone. However, minimizing them gradually brings us to 100% availability.
Very important: This “red” can be converted into production revenue, whereby PROXIA technology allows the individual faulty contributions to be recorded with great meticulousness in record time and to work specifically on their elimination - to put it casually: “Red becomes colorful”.
A CIP control loop is composed according to the current state of modern understanding of methods: planning - performing - checking - applying. PROXIA MDE plays the central role of "application" and PROXIA action manager for "checking". PROXIA machine data acquisition not only provides the employee at the machine with all the data necessary for order processing (using the pull principle), but also ensures through messenger services and bidirectional connection with PROXIA MES that they can intuitively communicate comments about deficiencies (push -Principle). PROXIA MES uses the eyes and ears of the employees as sensors for recording the actual processes in order to document the reasons for the downtimes of the systems. The person responsible for CIP assigns the causes of the absenteeism to certain categories via the PROXIA Action Manager. He can thus evaluate them at a glance and derive measures. This also makes it possible to detect “productivity funnels” (productivity drops) around the shift change, for example that no transports take place for half an hour as a result of the fork lift truck being handed over.
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