Introducing TPM - ABMA

Presented by Adrian Pask and Matthew Mettelman

Vorne Industries, Chicago

Introducing TPM

IntroductionsWe help manufacturing companies to improve productivity

▪ Adrian: OEE implementation and improvement projects

▪ Matt: XL production implementation and 90-day trial management

▪ Vorne has been manufacturing industrial electronics since 1970.

▪ 25,000+ “XL” OEE systems installed across >43 countries.

Vorne An Exceptional PartnerImproving manufacturing since 1970.

▪ 50 years of experience manufacturing industrial electronics

▪ Market leader in production monitoring solutions and analytics

▪ 25,000+ installations in 45+ countries

Introducing XL Vorne – Your Partner in Success

More ResourcesRecognized leaders in our industry

▪ Broad range of manufacturing improvement topics covered on our websites

▪ www.oee.com

▪ www.leanproduction.com

IntroductionsThe start of my TPM/OEE Journey

▪ Old 1940’s facility, under-invested, old production lines

▪ “Turnaround or Close”

▪ Average OEE 55% increased to 83% over 5 years

▪ Enabling lots of investment, including a state-of-the-art distribution center

▪ Manufacturing excellence is: “Doing simple things exceptionally well”.

IntroductionsReduced changeover from 60min to <10min, across European Supply Chain

Downtime Slashed by 94%

“The XL displays definitely generate a competitive interest on the plant floor.

Until we put the display up, it was not uncommon to see 160 minutes of shift downtime.

Now that the operators can see down time in real time, it is down just 10 or 12 minutes per shift.”

Case Study

S. T. | Plant EngineerInternational Glass Products Manufacturer

Before XL After XL

Down Time

OEE Improved by 22%

“So far this year, we have been able to achieve a 22% improvement in OEE, and XL has been an integral part of our improvement process.

By knowing the status of all our lines in real-time, we can address problems in real time.”

Case Study

M. H. | Plant ManagerPersonal Care and Household Products

Before XL After XL

What is TPM?An holistic approach to equipment maintenance.

▪ Introduced to the West by Seichii Nakajima in 1988.

▪ Consultant with the Japanese Institute of Plant Management

▪ Striving to achieve:▪ No Breakdowns

▪ No Small Stops or Slow Running

▪ No Defects

▪ No Accidents

▪ It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.

What are the components of TPM?

TPM is often presented as a set of processes, arranged in a structure

▪ Sensei Chihiro Nakao (Toyota: 27 years):

“Americans think that 5S is all about the housekeeping and orderliness of the workplace.

We use your 5S status to understand the orderliness of leaderships’ mindset.

If they do not have the discipline to maintain their 5S, they will not have the discipline to succeed in the other aspects of TPS”

Overall Equipment EffectivenessCross-Industry best practice

▪ OEE originally documented as part of TPM

▪ Easily applies to discrete manufacturing plants and processes

▪ Provides a consistent view of all your assets

▪ Provides one framework for seeing all loss information

Perfect Production = 100% OEEIdentify the percentage of production time that is truly productive

100% OEE = “Perfect Production”

(Making only good parts, at full speed, with no stops)

OEE (when used properly) exposes production loss

OEE, TEEP and 6 Big Losses

Overall Equipment EffectivenessThere’s no such thing as “World Class” OEE

▪ The real value behind OEE is not tracking what you made….it’s in tracking what you LOST

▪ Many people get obsessed with “The 85% Myth” (convenient, compelling, completely artificial)

▪ Set targets that incrementally reduce your losses.

▪ Resist the urge to compare your OEE scores, especially for dissimilar processes

How do we capture OEE?Start manually, automate incrementally

▪ Manual - typically with a MS Excel spreadsheet

▪ OEE Tracking System (on-site or cloud based)

▪ MES system (often an optional module)

▪ ERP system (typically doesn’t connect to machines)

How do we apply OEE?Information only adds value when it’s used to identify an action

▪ Information: Foundation for Decision Making. OEE is a type of Information.

▪ Decisions: The Pivot between Information and Actions. The moment in time when Information is reviewed, and a course of Action is decided.

▪ Action: Where possibilities become tangible improvements; where decisions are transformed into Results.

All Three Factors are Needed

▪ The gauges are inaccurate or broken (Information problem)

▪ The gauges are accurate, but you don't use them (Decision problem)

▪ The gauges are accurate, and you look at them; but you don't make any adjustments to the flight controls (Action problem)

Leverage OEE in Meetings

Pick a meeting that:

▪ Happens regularly

▪ Can be easily changed

▪ Can be reinforced

▪ Will quickly make a difference

Daily Production Meetings are my favourite

The right actions, by the right people

Operational: Fix problems, completing changeovers, replenishing materials, completing maintenance, escalating problems.

Tactical: Planning changeovers, maintaining standard work, ensuring that machines are maintained to schedule, identifying “100yr fixes” to problems.

Strategic: Improving standard work, applying improvements across work centers, capital projects and TPM management.

Presented by Adrian Pask and Matthew Mettelman

Vorne Industries, Chicago

Introducing XL

Instant OEEThe gold standard for manufacturing productivity.

▪ OEE delivered by the publishers of oee.com

▪ Six Big Loss reports delivered by the publishers of leanproduction.com

▪ TEEP reports to expose your “hidden factory”

Installation Friendly

Easily installed by your maintenance team.

▪ One or two sensors

▪ Barcode scanner

▪ Ethernet drop

Empower your plant f loor team.

▪ Immediately improve productivity with real-time targets for operators

▪ Choose from 100+ KPIs with point-and-click scoreboard configuration

▪ TAED (Target, Actual, Efficiency, Down) often used so operators can “win the shift”

▪ Scoreboard automatically changes context (e.g., down, changeovers, breaks)

Visual Factory

Ru n n in g No rm a l l y

P ro d u c t i o n S t a t e S c re e n s

Any MachineOne platform for every process.

▪ Easily applies to all your plants and all your processes

▪ Provides a consistent view of all your work centers

▪ One framework for seeing all loss information

▪ Scales from work center to enterprise

Track DowntimeAutomated. Accurate. Actionable.

▪ Replaces highly inaccurate manual log sheets

▪ Automatic, precise, run/down detector

▪ Operators are prompted to scan reasons for out-of-the-box analytics

▪ Add comments to key events to capture additional insights

▪ Companies are often shocked when they discover their true down time

▪ Factors into OEE Availability (together with changeovers)

Repor ts fo r Your Ent i re Team

Scoreboard fo r Opera tors

A real-time view of manufacturing.

▪ See data from anywhere on your network

▪ Visualize production in real-time during the shift

▪ Color-coded events expose issues, identify patterns, and encourage immediate action

▪ Instantly see downtime, changeovers, production, and breaks

▪ Tooltips provide complete loss reports for every event

Visualize Production

Top LossesA built- in continuous improvement roadmap.

▪ Losses prioritized and ranked by their time impact

▪ Sparklines show trends and patterns

▪ Additional details and context for each loss

▪ Provides instant clarity on what to fix next

▪ Spend more time improving and less time in meetings

Your entire enterprise at a glance.

▪ A complete hierarchical view of sites, areas, and work centers

▪ Automatic rollup of data across all levels

▪ Color calls attention to where actionis needed

▪ Multiple built-in views or configure your own

▪ All from the XL device – no servers or software to install, no recurring fees

All Production

† US Do m e s t i c P r i ce s

Transparent PricingEasy to use. Easy to buy.

▪ Select the scoreboard model that best fits your needs

▪ Three models - all with identical features and reporting capabilities

▪ No recurring license, maintenance, or support fees

▪ Attractive expansion discounts

XL 8 1 0 -1 $ 3 , 9 9 0 † XL 6 1 0 $ 2 , 9 9 0 † XL 4 1 0 $ 1 , 9 9 0 †

A great investment that grows with you.

▪ Visit www.vorne.com/new to see what’s new for XL

▪ Free software updates

▪ Free technical support

▪ 3-year warranty

▪ Deep ecosystem of international, developer, and consulting partners

▪ Improvement best practices are integrated into the platform

A Platform for You

Introducing XL An Excellent Value

Try XL in your plant.

▪ Start with a webinar where we focus on YOUR application and YOUR questions

▪ We’ll send you a trial unit of your choice

▪ Trials have full support from Vorne –test our support as well as our product

▪ Streamlined process – we’ve successfully completed 2,000+ trials

▪ Nine out of ten trial customers buy XL

Free 90-Day Trial

Introducing XL An Excellent Value

sales@vorne.com

+1.630.875.3600

www.vorne.com

Thank you

Installs in hours.

Configures in minutes.

Impacts immediately.

Introducing XL

Introducing XL W hat is XL?

What is XL?

A Simple Solution Sl i d e 8

A Powerful Platform Sl i d e 1 2

An Excellent Value Sl i d e 2 9

Vorne – Your Partner in Success Sl i d e 3 4

What is XL?An IoT device with fully-integrated production monitoring and reporting.

▪ One device that includes scoreboard, I/O, historian, and reporting

▪ A “bolt-on” solution for monitoring any manufacturing process

▪ Centralized reporting behind your firewall with no need for servers

▪ A single source of accurate and precise information on losses

▪ Simple to install, easy to integrate

▪ Eliminates manual data collection

▪ A complete solution at a fixed and transparent cost

Why XL?Installed in 25,000+ applications across all industries.

▪ Applies easily to all types of manufacturing processes

▪ Provides a uniform way to look at manufacturing performance across all your work centers

▪ Over 100 actionable metrics and dimensions

▪ Scalable – start with one work center and expand at your pace

▪ Unlimited users with no license, maintenance, or other recurring fees

▪ Fast and easy – avoids costly and complex projects

Case StudyDowntime Slashed by 94%

“The XL displays definitely generate a competitive interest on the plant floor.

Until we put the display up, it was not uncommon to see 160 minutes of shift downtime.

Now that the operators can see down time in real time, it is down just 10 or 12 minutes per shift.”

S. T. | Plant EngineerInternational Glass Products Manufacturer

Before XL After XL

Down Time

Case StudyEff ic iency Increased by 29%

“We saw an immediate 29% improvement in production efficiencies just by adding the Vorne displays!

The project has been so successful that we’ve now outfitted two complete plants with XL800s and are working on another.”

R. H. | EngineerLarge Print Advertising Company

Before XL After XL

Efficiency

Case StudyOEE Improved by 22%

“So far this year, we have been able to achieve a 22% improvement in OEE, and XL has been an integral part of our improvement process.

By knowing the status of all our lines in real-time, we can address problems in real time.”

M. H. | Plant ManagerPersonal Care and Household Products

Before XL After XL

A Simple Solution

What is XL? Sl i d e 2

Installation Friendly

Easily installed by your maintenance team.

▪ One or two sensors

▪ Barcode scanner

▪ Ethernet drop

IT FriendlyLitt le or no impact to IT.

▪ No servers or software to install

▪ Operates on your LAN and behind your firewall

▪ Instant browser-based reporting

▪ Minimal impact to network traffic

▪ Off-the-shelf ERP/MES integration tools from our partners

User FriendlyThe most important XL feature isEasy. We call it XL Easy.

▪ Easy to install – one or two sensors, barcode scanner, Ethernet

▪ Easy to configure – point-and-click

▪ Easy to use – consistent and intuitive reporting platform

▪ Easy to leverage – immediate insights into all types of losses

▪ Easy to expand – add XL devices and data rolls up across your plant

A Powerful Platform

Any MachineOne platform for every process.

▪ Easily applies to all your plants and all your processes

▪ Provides a consistent view of all your work centers

▪ One framework for seeing all loss information

▪ Scales from work center to enterprise

Any MetricInstant access to a wealth of information.

▪ 100+ metrics and dimensions

▪ Metrics measure a quantitative characteristic of production

▪ Counts, Rates, Cycles, Quality

▪ OEE, Six Big Losses, TEEP

▪ Labor, Targets, Production Times

▪ Dimensions capture a qualitative characteristic of production

▪ Shift, Team, Part, Job

▪ Production State, Impact, Production Phase, Reject Reason

▪ Shift Hour, Day, Week, Quarter

Track DowntimeAutomated. Accurate. Actionable.

▪ Replaces highly inaccurate manual log sheets

▪ Automatic, precise, run/down detector

▪ Operators are prompted to scan reasons for out-of-the-box analytics

▪ Add comments to key events to capture additional insights

▪ Companies are often shocked when they discover their true down time

▪ Factors into OEE Availability (together with changeovers)

Scoreboard for Operators

Repor ts for Your Ent i re Team

Analyze CyclesPrecise measurement of run cycles and small stops.

▪ Automatically measures and categorizes every cycle

▪ Deep analytics with 18 built-in cycle metrics

▪ Validate run cycles to ideal cycle time for accurate OEE scores

▪ Small stops are differentiated as they often have a different root cause

▪ Equipment cycles tracked for asset-care programs

▪ Factors into OEE Performance

Explore QualityQuality metrics and reject reason as a dimension.

▪ Automatically track startup and production rejects

▪ Identify emerging issues with trend analytics

▪ Scan reasons for additional depth of reporting

▪ Use dimensional analysis to better understand underlying causes

▪ Factors into OEE Quality

Visual FactoryEmpower your plant f loor team.

▪ Immediately improve productivity with real-time targets for operators

▪ Choose from 100+ KPIs with point-and-click scoreboard configuration

▪ TAED (Target, Actual, Efficiency, Down) often used so operators can “win the shift”

▪ Scoreboard automatically changes context (e.g., down, changeovers, breaks)

Ru n n i n g No r ma l l y

P r o d u c t i o n S t a t e Sc r e e n s

A real-time view of manufacturing.

Visualize Production

▪ See data from anywhere on your network

▪ Visualize production in real-time during the shift

▪ Color-coded events expose issues, identify patterns, and encourage immediate action

▪ Instantly see downtime, changeovers, production, and breaks

▪ Tooltips provide complete loss reports for every event

Instant OEEThe gold standard for manufacturing productivity.

▪ OEE delivered by the publishers of oee.com

▪ Six Big Loss reports delivered by the publishers of leanproduction.com

▪ TEEP reports to expose your “hidden factory”

Top LossesA built- in continuous improvement roadmap.

▪ Losses prioritized and ranked by their time impact

▪ Sparklines show trends and patterns

▪ Additional details and context for each loss

▪ Provides instant clarity on what to fix next

▪ Spend more time improving and less time in meetings

Take a Deep DiveInstant answers to important questions.

▪ Simple – Q&A format

▪ Natural – for example: “Am I running close to my ideal cycle time?”

▪ Powerful – based on best practices from thousands of deployments

▪ Productivity: OEE, Six Big Losses, TEEP

▪ Losses: Down Time, Changeover, Performance Loss, Quality Loss

▪ Labor: Teams and Labor

Advanced Analytics

Explore. Compare. Trend. Improve.

▪ Explore dimensions and metrics with an intuitive drag-and-drop interface

▪ Compare across dimensions to discover connections and causality

▪ Trend metrics to see which KPIs are improving and which are getting worse

▪ Improve and validate the impact of your actions with personalized data views

All ProductionYour entire enterprise at a glance.

▪ A complete hierarchical view of sites, areas, and work centers

▪ Automatic rollup of data across all levels

▪ Color calls attention to where action is needed

▪ Multiple built-in views or configure your own

▪ All from the XL device – no servers or software to install, no recurring fees

Live DashboardsPoint-and-click to create your own reports.

▪ Personalize each view to visualize whatever is most important to your team

▪ Incorporate table, chart, chronogram, KPI, and KPI group widgets

▪ Instantly export any table to Excel

▪ Exactly what you want to see, exactly how you want to see it

Heat MapsProblems practically leap from the page.

▪ Perfect for quickly scanning to spot problem areas

▪ Available for charts, tables, chronograms

▪ Define levels for each alert metric: Good, Caution, Warning, Critical

▪ Continuous color gradient for highly expressive pages

Add Context with Comments

Add freeform comments to any event.

▪ Provide additional context for major losses

▪ Post comments and replies

▪ Easily search across all comments

▪ Create personalized views to validate policy-based audits

▪ For example: Down > 15 minutes, Part OEE < 65%

Free cloud services for the XL platform.

▪ Instant notification for anything that needs your attention

▪ Automatically escalate alerts to supervisors and managers

▪ End-of-shift reports immediately delivered directly to your inbox

Email Alertsand Reports

An Excellent Value

Vorne – Your Partner In Success Sl i d e 3 4

Transparent Pricing

Easy to use. Easy to buy.

▪ Select the scoreboard model that best fits your needs

▪ Three models - all with identical features and reporting capabilities

▪ No recurring license, maintenance, or support fees

▪ Attractive expansion discounts

XL 8 1 0 $ 3 , 9 9 0 † XL 6 1 0 $ 2 , 9 9 0 † XL 4 1 0 $ 1 , 9 9 0 †

† US Do me s t i c P r i c e s

Unbeatable ValueA standardized off -the-shelf product that easily adapts to you.

▪ All features included for one low cost

▪ Match XL to your process with point-and-click configuration

▪ No custom software

▪ Free cloud services including email alerts

▪ Built on manufacturing best practices and our experience from 25,000+ installs

▪ Third-party standard products for easy integration

A Platform for YouA great investment that grows with you.

▪ Visit www.vorne.com/new to see what’s new for XL

▪ 3-year warranty

▪ Deep ecosystem of international, developer, and consulting partners

▪ Improvement best practices are integrated into the platform

Free 90-Day TrialTry XL in your plant.

▪ Start with a webinar where we focus on YOUR application and YOUR questions

▪ We’ll send you a trial unit of your choice

▪ Trials have full support from Vorne – test our support as well as our product

▪ Streamlined process – we’ve successfully completed 2,000+ trials

▪ Nine out of ten trial customers buy XL

Vorne – Your Partner In Success

Vorne An Exceptional Partner

Improving manufacturing since 1970.

▪ 50 years of experience manufacturing industrial electronics

▪ Market leader in production monitoring solutions and analytics

▪ 25,000+ installations in 45+ countries

Manufacturing Improvement Experts

Recognized leaders in our industry.

▪ We publish oee.com and leanproduction.com

▪ We present at industry and corporate conferences

▪ We educate with improvement topics and techniques

▪ We innovate with patented technologies

Global Reach19 international partners. 45+ countries.

▪ ACI Belgium

▪ BIMSO Colombia

▪ Cogent Automation India

▪ C9 Business Solutions Dominican Republic

▪ Gestion Operacional Chile

▪ IFD Representatives Ecuador

▪ Lean Solución Mexico

▪ Lean Expert Puerto Rico

▪ Line Andon Egypt

▪ LineView Solutions UK

▪ Prodasis Mexico

▪ RSquare Konnect India

▪ S4 Automation South Africa

▪ TQMsoft Poland

▪ Trinity Business Solutions Brazil

▪ Vetii | TECH USA

▪ Vince Soluções e Tecnologia Brazil

▪ Workflow Ltd New Zealand

▪ ZIN Corporation South Africa

You’re InGood Company

XL is trusted by thousands of companies.

▪ Driving improvement across the full spectrum of manufacturing

▪ Applies easily to different processes and industries

▪ Click here to see companies using XL within different industries.

▪ Click here to see comments from our customers

Why Choose XL?

XL is Powerful

▪ Complete visibility of manufacturing lines

▪ Integrated scoreboard and reports

▪ 100+ metrics and dimensions

▪ Rolls up data across plants

▪ Configurable dashboards

▪ Built-in, shared, personal views

XL is Affordable

▪ One-time cost

▪ No fees or licenses

▪ No contracts

▪ No limits on users

▪ Free cloud services

▪ 90-day free trial

XL is Easy

▪ Installs in hours

▪ Incredibly easy to use

▪ No additional staff needed

▪ Proven global platform

XL is your fastest path to improving manufacturing productivity.

Email sales@vorne.com

Call +1.630.875.3600

Visit www.vorne.com

Thank you

Introducing TPM - ABMA

Documents

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