As a manufacturer with machines, your main challenge is quality production with the best equipment availability and maximum performance.
So when you notice performance problems, you will quickly realize that the manual methods used to measure performance losses are no longer appropriate, as they slow down your speed of analysis of the situation and are therefore a brake on your dynamics of change.
In this context, the integration of a tool dedicated to performance monitoring makes sense and will become an ally in your Lean approach to improve the performance of your machines.
The different types of machine performance losses
The causes of loss of performance can be numerous, however, there is a known list that lists the majority of cases of performance loss encountered in an industrial environment. You will find this list below, but it should be noted that it is not exhaustive and that it is possible to identify other cases of loss in your company.
Losses related to equipment
- Losses due to breakdowns
- Losses due to adjustments
- Losses due to tool changes
- Start-up losses
- Losses due to micro-stops and idling
- Loss due to under speed
- Losses due to defects and alterations
- Losses due to program shutdowns and shop closure
Labour-related losses
- Losses due to management
- Losses due to speed of execution
- Losses due to line organization
- Losses due to logistics
- Losses due to measurements and adjustments
Losses related to materials, tools and energy
- Energy losses
- Losses due to tooling
- Losses due to material yield
OEE analysis with 16 TPM losses, Christophe Hohmann’s website: www.christian.hohmann.free.fr
From this list, you can make a targeted data collection based on the different performance drop events and determine their source.
Most industrial companies have an excellent understanding of the causes of efficiency losses that prevent them from achieving the performance of their machines.
In the majority of cases, these are “simple” problems that are often poorly addressed due to a lack of time, money or technical/managerial skills. The problem is therefore not the difficulty to identify problems but to measure them, prioritize them and above all to treat them in the right order of priority with the right corrective measures.
How to give people simple and intelligible information to help them in their decision making and support them in their approach to improving performance ? By giving them transparency on the causes of non-performance of their assets (technical but also human) and supporting them in taking improvement actions.
A dedicated monitoring tool to facilitate your improvement process
A performance monitoring tool can help you structure and have a quick analysis of the sources of performance loss by classifying the events at the origin of these events and to determine the main sources of performance loss and provide areas for improvement.
This analysis of the sources of loss must be specific to your company, in fact, it is up to you to define the source of your event causing the loss for example defects in maintenance, quality, managerial …
Only customization will allow you to adapt and above all facilitate the use of the tool so that daily actions change and generate more value for the company.
Below are the typical added values that such a tool would bring to your organization:
For the operator : Allows automatic communication on shutdowns, real time knowledge of his production rate.
For the manager : Real-time status of equipment operation, simplified analysis, rapidity of improvement proposals.
For maintenance :Analysis of the causes of recurring losses will allow to adjust or define a maintenance system.
For the management : Provide elements that will allow a better analysis of the equipment load rate and thus guide the investment policy or the organization of the teams.
All the members of your organization will have all the important data to implement an improvement process quickly, efficiently and transparently.