Profit Finders Booklet

We discoverhidden costsavings.

Energy Water Chemicals Waste Treatment

A FEW

OF OUR

CUSTOMERS.United States Department of Energy

“A typical industrial facility can realize savings of up to

25 percent in process heating systems, up to 20 percent in steam

systems, and as much as 18 percent in motor systems.”

US Department of Energy - Energy Savers Web Site www.energysavers.gov

“…cut cleaner consumption by 17% per year for

2 consecutive years”

“...natural gas usage decreased 30%”

www.profitfinders.net

WHO

&

HOW

WE HELP.

TYPICAL MANUFACTURING PROCESSES.

• Coating and Finishing Operations

• Metal Forming Operations

• Energy Tracking by Process

• Waste Treatment Optimization

• Plant Air and Utilities

INCREASE YOUR BOTTOM LINE.

• Reduction in Direct Utilities by Process

• Reduction in Process Chemicals and Other Inputs

• Lower Scrap, Rework and Rejects

• Benchmarking and Optimization by Shift

• Accelerated Line Staff Training and Accountability

WHAT

WE DO.

We put a spotlight on a process to ensure waste is eliminated.

We develop a way to measure process performance enabling continuous improvements.

GAS

WATER

WASTE

ELECTRICITY

CHEMICALS


“...27% coolant use reduction”

“…eliminated over $100,000 of waste treatment costs”


OUR

PROCESS.

STEP 1.We provide the latest proprietary hardware to measure a process.

STEP 2.Data is captured and transferred through the Internet.

In God we trust. All others must bring data.

W. EDWARDS DEMING

STEP 3.We develop meaningful reports that are available on-line, real-time.

STEP 4.We analyze the data and identify opportunities for continuous improvement and significant cost savings.

WE DRIVE

CONTINUOUS

IMPROVEMENT

PROJECTS.

In the long run, men only hit what they aim at. Therefore, though you should fail imme-diately, you had better aim at something high.

HENRY DAVIDTHOREAU

www.profitfinders.net www.profitfinders.net

OUR

RESULTS.

BEFORE PROFIT FINDERS.

Processes typically see wide variations. From this data, we develop a benchmark for process improvement.

PHASE 1.

We catch anomalies in real-time, identifying opportunities to reduce process variations and establish a steady state process.

It’s a funny thing about life; if you refuse to accept anything but the best, you very often get it.

SOMERSETMAUGHAM

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YOUR

PROCESS

WATCHDOG.

PHASE 2.

We provide the reports, data and recommendations to tighten control limits and reduce target usage.

PHASE 3.

We become the 24-hour watchdog of your process to ensure your savings are maintained over time.

How long does it take you, as a boss, to achieve world class quality? Less than a nanosecond to attain it, a lifetime of passionate pursuit to maintain it.

TOM PETERSTIME

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ACTIONABLE

INFORMATION.

Errors using inadequate data are much less than those using no data at all.

CHARLESBABBAGE

• Daily summaries and weekly reports detailing process performance and associated cost delivered to your in-box.

•On-line access to real-time data.

•Quarterly program review in which we provide recommendations for process improvements.

We are experts at converting data into usable/actionable information.

OUR REPORTS.

Our reporting tools are available on-line 24/7 through our Data Center... access overviews of cost control to minute-by-minute process detail.

DATA CENTER. All reports are generated from our intuitive dashboard.


DATA CENTER - MONTHLY BREAKDOWN. An example of natural gas

• Click on any day to drill down to minute-by-minute details

DATA CENTER – DAILY BREAKDOWN. An example of minute-by-minute details overlaid with another parameter.


STATISTICAL ANALYSES.


LEAN SIX SIGMA TOOLS.


DMAICD: Define: Process Maps, VOC, SIPOC, CTQ Tree, Kano Analysis

M: Measure: VSM, OEE, Run Charts, FMEA, SMED, Takt Time

A: Analysis: Control Charts, 5 Why’s Analysis

I: Improve: Kaizen Event, Setup Reduction, 5-S Program, Error Proofing, TPM

C: Control: QC Process Chart, Before & After Charts

Calculating OEE Worksheet

Production DataShift Length 8 Hours = 480 MinutesShort Breaks 2 Breaks @ 10 Minutes Each = 20 Minutes TotalMeal Break 1 Breaks @ 25 Minutes Each = 25 Minutes TotalDown Time 50 MinutesIdeal Run Rate 80 PPM (Pieces Per Minute)Total Pieces 19,271 PiecesReject Pieces 423 Pieces

Support Variable Calculation ResultPlanned Production Time Shift Length - Breaks 435 MinutesOperating Time Planned Production Time - Down Time 385 MinutesGood Pieces Total Pieces - Reject Pieces 18,848 Pieces

OEE Factor Calculation My OEE%Availability Operating Time / Planned Production Time 88.51%Performance (Total Pieces / Operation Time) / Ideal Run Rate 62.57%Quality Good Pieces / Total Pieces 97.80%Overall OEE Availability x Performance x Quality 54.16%

OEE FactorWorld Class My OEE%

Availability 90.00% 88.51%Performance 95.00% 62.57%Quality 99.90% 97.80%Overall OEE 85.00% 54.16%

Fill in the highlighted areas with your production data for a single shift. In some cases, you may have to convert units to simplify the calculation. For example, 3600 PPH (Pieces per Hour) is 60 PPM (Pieces per Minute).

It is easy to lie with statistics, but it is easier to lie without them.

CHARLES FREDERICK MOSTELLER

YOUR

RESOURCES.

Science is made up with facts, as a house is with stones. But a collection of facts is no more a science than a heap of stones is a house.

JULES HENRI POINCARÉ

•Our IT and installation engineers tailor your system to deliver reliable and informative reporting designed specifically for your process.

•We dedicate an engineer to review your data weekly and lead quarterly program review meetings to identify easy to implement cost saving ideas.

•Our entire team is dedicated to ensure you maximize your savings and your process never slips back to less than optimal performance.

OUR PEOPLE.

Experienced chemists, engineers and process managers on one team

to help you save money.


CONTINUOUS

IMPROVEMENT.

ALARMS AND LIMITS. Alarm emails allow for remote monitoring.

There are two kinds of statistics: the kind you look up and the kind you make up.

REX STOUT


There is nothing so useless as doing efficiently that which should not be done at all.

PETER DRUCKER

WHAT WE

NEED FROM

YOU.• On-site assistance installing our system.

•Input on appropriate cost benchmarks to be used for future cost saving calculations.

•Desire to improve and save money!

WHAT WE NEED FROM YOU.


PRICING.

A low cost, low risk way to outsource continuousimprovement projects.

• Monthly Fee For A Typical Project Is $1,500

• NO LONG-TERM COMMITMENT REQUIRED

• We Provide All Hardware, Software & Firmware

• First Two Months Are Used As Baseline

• Cost Savings Tracked To Ensure Program Is Self-Funding

It is a capital mistake to theorize before one has data. Insensibly one begins to twist facts to suit theories, instead of theories to suit facts.

SHERLOCKHOLMES

OUR PRICING.


A FEW

MORE

OF OUR

CUSTOMERS.

The wise man bridges the gap by laying out the path by means of which he can get from where he is to where he wants to go.

JOHN PIERPONT MORGAN


We add proprietary sensors to measure all important process parameters

We collect, organize & report back data

We review your data to initiate process improvements

We identify improvements that provide the fastest ROI

We deliver cost savings documentation

Massachusetts Institute of Technology

“… manufacturers have primarily been concerned more about

price, quality, and cycle time than with how much energy

their manufacturing processes consume.”

Study led by Dr. Timothy Gutowski of MIT – Funded by the National Science Foundation

Quality is free.

PHILIP CROSBY

To schedule an online demonstration of how Profit Finders can help you meet

your continuous improvement and cost reduction goals...

Call 440-638-5214 or go to www.profitfinders.net

20338ProgressDrive•Strongsville,Ohio44149•440-638-5214


Profit Finders Booklet

Documents

minute process

process performance

process reduction

process improvements

process variations

process chemicals

process maps

process processwe