Improving Packaging Line Performance –Using the correct Data and Drill Down Analysis
Actionable Information III
www.optimumfx.com
Data…Data…Data == Good Information
Excessive data – Lack of information The right data – with drill down analysis
X
Actionable Information
Actionable Information
1. What’s the right data to focus on the right areas?
Causal (loss to critical machine
Actual time
Machine stoppages
PDT/NOP
2. How can this be categorised in a useful way? And Why?
Six loss data
Counter-measure for
each loss
3.How can we focus our efforts ?
?
Site
Drill Down – What it should be
Categorise Changeover Review Loss
vs Target
Cause
Machine
Fault
Review Changeover Effectiveness
Critical Machine Actual vs
Rated Speed Review Line Balance
Categorise Reject Loss
Review Loss vs Target
Data Drill Down - Tactical LineView
Six loss
Cause pareto
Machine causal loss
Machine fault
OEE vs Total Loss
OEE60%
LineView loss screen
LineView status screens
Data Drill Down - Strategic in LVR
Breakdowns and Minor Stops DrilldownCausal Loss Pareto
Loss Trend
Faults Pareto
Fault Trend
Actionable Information
1. What’s the right data to focus on the right areas?
Causal (loss to critical machine
Actual time
Machine stoppages
PDT/NOP
2. How can this be categorised in a useful way? And Why?
Six loss data
Counter-measure for
each loss
3.How can we focus our efforts ?
Drill down data Real-time, Summary data & trends
?
Problem Solving• Convergent processes
• Divergent processes
Lots of ideas or opinions
Convergent process
A specific problem or
issue in time
Divergent process
Create many different
options for action
Identify one specific action
Types of process:• Any process that funnels
your thinking• Decision Analysis• 5 Whys
Types of process:• Any process that creates
ideas• Brainstorming• Ishikawa/Fishbone
Picking the right tool for the job
Quick and easy
Detailed and robust
Large problem
Small problem
e.g. 5 Whys
May be an individual or team event
Can be highly subjective and unrepeatable.
Ideal for providing structure for highly skilled individuals
e.g. Ishikawa/ Fishbone diagrams
Live on-going process for teams or individuals with defined outcome
Makes possible cause transparent through online documentation
Ideal for providing a structured approach for every day issues
e.g. Formal RCA/ PDCA process
Global 8D
KT Problem analysis
Typically an off-line analysis event
Highly transparent and replicable – will guide team to find new
knowledge rather than rely on existing
Ideal for tackling and closing complex issues
Trended Data - Event in TimeData Analysis
• Downtime loss average trended up from around 250mins per week to around 350mins per week
• This happened around week commencing 2nd of February
• What changed just before this week?
Problem Solving Process
• Convergent thinking
• Suggested tool – 5 Whys
Trended Data – Incremental Increase
Data Analysis
• Downtime loss average incrementally trended up from around less than 200mins per week to over 600mins per week
• This started happening from 2nd week of March and progressively got worse
Problem Solving Process
• Divergent thinking
• Suggested tool – Ishikawa/Fishbone
Trended Data – Consistent High Loss
Data Analysis
• Overall the Loss has reduced from around 1000mins per week to around 700mins per week, however it is still above target, consistently high and does not show an overall downward trend
Problem Solving Process
• Divergent and then Convergent thinking
• Suggested tool(s) – Global 8D or KT Problem Analysis
Actionable Information
1. What’s the right data to focus on the right areas?
Causal (loss to critical machine
Actual time
Machine stoppages
PDT/NOP
2. How can this be categorised in a useful way? And Why?
Six loss data
Counter-measure for
each loss
3.How can we focus our efforts ?
Drill down data Real-time, Summary data & trends
Problem solving – choose best tool