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Another issue is that most manufacturers have a tendency to not collect data
real-time, or automate their data-collection process, Atluru said. “When you manu- ally collect the data, there is always a possibility to introduce more variability, or more errors, into your data.”
Using financial OEE tied to manufacturers’ lean efforts also is important, noted consultant Robert Hansen, owner of R.C. Hansen Consulting LLC (Fort Collins, CO) and author of “Overall Equipment Effectiveness: A Powerful Production/Mainte- nance Tool for Increased Profits.” “Lean is the bigger umbrella, but OEE in my mind is the engine,” Hansen said. “In
the flow stream, I envision it as the pistons in the engine. I contend that OEE Value Stream analysis is extremely important to learn, and it can harmonize that engine.” The key to his approach is that all inventory is a loss, although necessary, said Hansen, a 29-year veteran of Eastman Kodak Co. “Financial OEE is the crystal ball that tells you just what the impact on the bottom line is,” Hansen said of OEE. “What it has is all the operating cost of the inventory. There are those who do it well, and others that have way too much inventory. Financial OEE just looks at whatever your current results are, from an income/profitability standpoint. The question is how much could you do if you did best practices?” An organization’s financial OEE is really a question of how well it’s doing cur-
rently, as opposed to how well it could do if the company was operating at world- class quality levels, he added. “If you use all that improvement in time, you’d be astounded that operations that are in the 60–70% at each shop workstation could be much better,” Hansen said. “There’s a complete hidden factory within the assets you already have. Most people don’t ask the question, ‘How much did I leave on the table?’ But they should be.”
Taking the Pulse of the Factory To enhance process improvement, manufacturers can leverage MTConnect to
more easily view operational performance, noted Surya Kommareddy, business development manager, DMG / Mori Seiki USA Qualified Products (DMGMSQP)- software, DMG / Mori Seiki (Hoffman Estates, IL). “If you don’t measure, you cannot manage,” Kommareddy said. “OEE is helpful, but probably as it stands it’s taking a broader view more focused on quality, availability and performance. That’s not enough. You need to have more insight into what’s going on to improve the process.”
MTConnect gives manufacturers access to a lot of information in real time, he added. DMG / Mori Seiki recently announced it would offer MTConnect Standard V1.1-compliant adapters with all new machine tools equipped with the company’s MAPPS control. The MTConnect adapter solution includes the adapter, an agent and web services to let customers monitor machine status. The effectiveness of OEE and charts depends on who looks at the metrics and how the data is used, Kommareddy said. “The shop manager may be interested mainly in OEE data,” he said, “but others are interested in that data on a de- tailed time chart. How many parts are being produced? And how many are being scrapped and why?”
July 2013 |
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