|
|
 |
 |
|
Overall Equipment Effectiveness in Food Production
Thomas R. Cutler, President & CEO, TR Cutler, Inc.
|
|
Few industries operate on as tight a margin as food manufacturing. The ability to develop accurate job cost data and production standards is make or break. According to John Rattray, Senior Executive with Canada-based, Memex, “We suggest a low cost, single machine ‘Pilot’ system, so companies can experience real-time monitoring, reporting and analysis of production and performance OEE data from all manufacturing equipments.”
Food Quality Assurance Managers are being instructed to prevent problems
and require a real-time performance OEE (Overall Equipment Effectiveness)
dashboard to view the plant. These data must capture metrics from each
machine as well as run time, down time, cycle time, production rate. Other
data needed include production and scrap counts and process (dwell,
duration, inject, form, fill) time.
“C-Level Food Executives also want Food Plant Managers to develop accurate job cost data and production standards, compare actual results against standards to ensure accurate product costing. This information must be accurate and technology solutions must deliver data with the ability to analyze performance by shift, department, lot, product and machine,” insisted Rattray.
It is vital in food operations whether complying with HACCP (Hazard
Analysis Critical Control Points) or ISO 22000 standards, that Operations
Managers are able to view plant performance data in real-time, anywhere,
anytime. The ability to select data functions to display is possible whether
viewed on any PC on the company LAN/WAN or via the web. Tracking production
in real-time to ensure goals are met and to minimize work-in-process are
essential to optimize food safety and production.
Memex identified the importance of eliminating unproductive labor and
manual data recording errors within the food industry production process.
Rattray said, “Food companies must be able to alert Managers to potential
problems with real-time E-mail and the E-mails must be sent automatically
when performance and OEE targets aren’t being met, or machine status or
operation changes.”
Rattray went on to suggest that improved scheduling with visual job queue and an optional ERP link to schedule and track job progress in real-time on each food production machine was very helpful: “Food production efficiency is enhanced with the ability to download ERP production requirements to job queue and then upload production data at job and shift end. Companies are able to benchmark processes and track results continuously.”
Supporting Lean Initiatives with Technology
These technologies support Lean Manufacturing, Continuous Improvement
and Six Sigma initiatives with accurate measurement of defined metrics and
key performance indicators. Using easy-to-understand graphical displays to
track progress, inform and motivate operators are essential in the food
sector given wide array of skill sets and knowledge levels.
Track and analyze OEE/TPM program Big Losses.
- Record downtime due to breakdowns and start-up
- Analyze speed losses due to small stops and reduced speed operation
- Measure quality loss by recording start-up and production rejects
Thomas R. Cutler is President & CEO of Fort Lauderdale, Florida-based, TR Cutler, Inc. He is the founder of the Manufacturing Media Consortium of three thousand five hundred journalists and editors writing about trends in manufacturing. Thomas is a member of the Society of Professional Journalists, Online News Association, American Society of Business Publication Editors, Committee of Concerned Journalists, as well as author of more than 400 feature articles annually regarding the manufacturing sector. He is also the developer of lean technology C.E.O (Continuous Experiential Optimization). For article feedback, contact Thomas at trcutler@trcutlerinc.com
|
|
|
|
|
|
|
 |
|
