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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 ToolERP systems are not suited to support the CIP organization. Real time ERP datacombined with machine data is required to visualize the real status of the shopfloor and to calculate a TRUE OEE. Planned vs. Actual Performance Analysis isthe key element of Shop Floor Management.
1. Leadership PrincipleShop 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 FloorManagement
OEE isn‘t used as KPI as management tool.
No online visualisation.
Manual data collection(Lean Dogma: Data collected by
machine operators)
Far from RealityManagement Style:
”Management by Remote Control“
Reliable, automated and objective performance analysis.
Transparency through real-time visualisation and all KPIs at a
glance.
Based on realityManagement 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 toknow 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 performanceinformation in real time will give the operator immediate feedback about thecurrent performance of his manufacturing workplace in order to take immediatemeasures in the case of a deviation from target.
How are you currently measuring shop floor performance?
Planned-Actual Comparison
Traditional Method Advanced Shop FloorManagement
R E A L - T I M ER E L I A B L E
D A T A
M A N U A LC 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 mustsupport all organizational roles within the CIP Organization.
All manufacturing roles are supported by advanced shop floor managementtechnology with no exceptions, from the machine operator to maintenance to theplant 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 OrdersWork 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 / DowntimesProduction FlowOrganizationQuality
Advanced Shop Floor Management (SFM) technology offers closedloop CIP communication by delivering the right information to theright role at the right time
CIP Communication
Tools OptimizationsLogisticsWorker Orders / RoutingCurrent 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 recognizedimmediately 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 efficiencyfactor of standard ERP-software is enhanced due to the real-time data capture byFORCAM.
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 machineavailability by 10% in the 3 month test period.
SMART FACTORY
Measuring and optimizing the performance ofmanufacturing plants anywhere, anytime
The real-time information provided by FORCAMcan be accessed through mobile gadgetsincluding 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 ManufacturingExecution System (MES). It enables improvement processes on all levels of theproduction. Factory Framework™ connects, collects, and standardizes real-time datafrom most different machine controls. For every production level, the signalsprovide 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 continuousoptimization of the plant availability by eliminating errors and waste. The mostimportant key figure to measure the performance is the OEE – Overall EquipmentEffectiveness.
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 productivityby up to 20% within the first year, measured by TRUE Overall EquipmentEffectiveness (OEE).
Success Stories
© FORCAM 2016 www.forcam.com 17
FORCAMEUFORCAM GmbH (HQ)An der Bleicherei 1588214 Ravensburg
Tel.: +49 751/366 69 [email protected]
FORCAM LtdLumonics House
Valley Drive, RugbyCV21 1TQ, United Kingdom
[email protected] +44 (0)1788 247123
250 E. Fifth Street, 15th FloorCincinnati,
OH 45202, USA
[email protected] 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
电话 +86 21 6869 0126
FORCAMUK
FORCAMUS FORCAMCN
© FORCAM 2016 www.forcam.com 18
COPYRIGHT 2016 BY FORCAM GMBHD-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 GmbHAn der Bleicherei 1588214 RavensburgTelefon: +49 751 36669-0Fax: +49 751 [email protected]