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Literally, improving the efficiency of a production operation means raising the levels of attainment in three discrete areas of production;
1. Performance (or rate of production, e.g. metres/hr, tonnes/hr, bottles/hour)
2. Availability (or machine up-time)
3. Quality (or the proportion of good products produced as a %age of the whole number produced)
These can be considered on a machine-by-machine basis, by department, by site or as a business as a whole, all derivations will all be calculated from individual machine productivity data.
The three component parameters are used together to determine what is now regarded as the industry standard metric for indicating production efficiency, OEE (Overall Equipment Effectiveness). This metric is calculated by simply multiplying together the three individual %ages for the three component elements to obtain an overall performance figure.
This figure is a simple but very clear indication of just how a machine (or department or business) might be operating.
Although there are three important component measures, many companies will concentrate on any combination of these three parameters without associating them, it can be any number of the three, they are often worked on individually by discrete departments. Although OEE is a simple indicating metric the complexity, resource and effort required acquiring the necessary data often limits the extent to which companies can engage in the OEE measuring regime.
One thing on which all companies agree however is that improvement in productivity, be it one or all three of the component elements, delivers in a significant improvement in profitability.
Improving the production efficiency of a manufacturing process is one of the most effective mechanisms for improving the profitability of an organisation. Very often the measures that need to be taken are not complex, nor are they costly to implement. The key to be able to make the changes is knowing where the losses in production occur.
Experience has taught us that there are a number of essentials that need to be established at the outset of this exercise.
1. Someone must be charged with championing the project
2. Buy-in needs to be established from all interested parties, from machine operators through to C.E.O.
3. There needs to be the understanding that everyone in the company will benefit from the project
4. The project will not reach an end point. Improvements will always be necessary even after the big gains are made in the early stages.
Once these basics are put into place the most crucial element of the exercise is the acquisition of production data. It is this productivity information that arms companies with the intelligence to make the changes necessary if improvements are to be made.
Small changes in productivity make large differences to profitability – and they are not difficult to identify.
AssetManager has been very cleverly designed to install and operate effectively on just about every automated production machine there is (non automated processes do not have any system to connect to).
This is possible because the fundamental OEE components are common across to manufacturing processes; the natures of the processes’ components (e.g. the downtime reasons) are specific to each process.
AssetManager’s interfaces, both the wired interconnections and the operator touch screen are easily configured to suit individual applications.
AssetManager operates on the InfoServe365 Internet technology platform. This platform has been installed and operating reliably since 2005. It has a centralised data centre (where the data is stored) with a web based hub topology (clients sites from where the data is gathered).
Access to the data and the analysis modules is gained via any normal web browser from any Internet connected computer (users must have appropriate security credentials).
We are very much aware that for projects like this to work, the buy-in of operators is essential so we designed the AssetManager interface to be intuitive and friendly to use. In our experience machine operators very quickly get used to the AssetManager interface and find its operation simple and interesting.
Its icon-lead menu interface is a very easy to for operators use. Icons that require attention flash, prompting the operator accordingly. The operator then has context sensitive options written in a choice of selectable languages
Data entry is therefore very quick to effect, something operators really appreciate.
The touch screens display some production performance information (event logging and trends on the screens themselves. So operators can see for themselves their performance attainments.
Only people specified by the customer can access the system. Access to the system is gained via the www.manufacturingintelligence.co.uk website and users require security credentials in order to access the system.
There is no limit placed upon the number of people that can be granted access and there is no per user cost associated.
People with access can only see data belonging to their company and each person with access can be withheld access to specific modules or reports as determined by the customer.
Yes. There are two options.
1) As standard the AssetManager system is supplied with a set of interface I/O (input/output) devices with which the system is connected to the host machine. This I/O block can be extended to include any physical parameter for which an electrical small signal is available.
2) The second technique involves the use of OPC technology. Here we connect the AssetManager system to the supporting digital host systems (with PLC, SCADA and similar) and gather any data that resides within those systems.
It is important to understand that these connectivity methods render the AssetManager system as non-standard. This will mean that the system will loose the auto-update facility i.e. when any firmware updates are issued by the AssetManager development team all AssetManager touch screens with standard firmware installed can automatically update to the latest version of operating system.
AssetManager has an energy module that will record the energy consumed (for any utility) and automatically associate the usage with productivity. This is one of the most powerful analysis activities that energy managers can hope to perform and often takes a great deal of time and effort to carry out. With AssetManager the whole activity is carried out automatically.
Many companies, large and small alike, use InfoServe365’s data collection and production reporting system. Names familiar such as Crown Paints, Kodak and Amcor, and perhaps less household-name companies such as Tensar International, The Bobst Group and Eurobond in Wales.
We have installations in prominent academic institutions such as Oxford University, and in overseas locations including the Far East and Europe.
We can offer a number of demonstration methods. We have an on-line demonstration of InfoServe365 (a bespoke application, which is similar but not identical to AssetManager) using a machine that we operate at our headquarters. With this demonstration we will make telephone contact with you at your own premises and using a computer with Internet access connect you to our demonstration site. We will then talk you through the demonstration and give you a good overview of the InfoServe365 functionality.
Alternatively, we have an authentic demonstration unit that we can either bring to a customers site or if you prefer we would be happy to accommodate you at our offices in Lancashire. Again this gives a first hand introduction of a real application.
For customers that are close to a commitment and would like to speak to an existing client, we have a number of sites that are willing to act as references and can occasionally accommodate site visits.
Operation of the touch screen is really simple and intuitive. In our experience machine operators very quickly get used to the AssetManager interface.
Its easy to read, icon-lead menu interface is a very good to for operators use. Icons that require attention flash, prompting the operator accordingly. The operator then has context sensitive options written in a choice of selectable languages.
Any conditions that can be acquired automatically require no operator input.
There are optional connections that feed back to the host control system. These prevent start-up of the machine until the operator enters valid data when required.
Access to the data, the analysis tools and the reporting modules is gained by logging on to the InfoServe365 website from any Internet connected computer using a normal web browser.
People wishing to logon require valid security credentials.
This means that access to the whole analysis system is possible anywhere in the world with Internet access. In the office, at home, whilst away on business and even roaming on your palm top or smart-phone.
With valid security credentials there is no practical limit to the number of customer nominated people that can access the analysis and reporting tools. There is no per-user fee charged. The single monthly service charge includes all access fees.
The system’s permission levels can be configured (by InfoServe365 technical staff only) to allow access to individual modules according to the customer’s request.
Yes. Generating bespoke reports is a complex and time-consuming exercise for anyone. We are happy to provide this service and will provide a quotation according to the content and complexity of the required report.
We advise customers to initially use the raw data module to access the process or production data of interest and export the data in a spreadsheet format. By carrying out some longhand analysis and report design a good report specification can be determined before its final hard production is carried out. This saves customers time and money.
Any data collected using the AssetManager system and stored on the InfoServe365 servers is owned exclusively by the client. InfoServe365 has no right of ownership over any data. Should the client request that any data is returned, InfoServe365 will do so and will delete all records of that data. The client is free to witness the deletion if they so wish.
There are fixed monthly service fees charged on a per application basis. There are neither additional operating system upgrade fees nor are there any additional per user fees.
The AssetManager service has a defined tariff. Please refer to our published terms and conditions. We will be happy to supply a copy on request.
Broadly, the service costs include for the provision of the service according to the stated uptime of 99.4%, include all operating system upgrades (for standard applications), access to the web service by any number of registered people (with security credentials) and ongoing telephone support.
We quote a standard delivery period of 3 weeks. We can often improve this but will confirm at the time of placing an order.
Overall Equipment Effectiveness, or OEE, is an industry standard indicator, expressed as percentage, which describes the level of production efficiency being attained for any industrial manufacturing process.
An efficiency improvement drive would firstly measure (or benchmark) a process’ existing OEE level then by analysing, identify where inefficiencies exist. Measures to address the causes would be introduced (with either new working procedures, new equipment or a more targeted maintenance regime).
Once the improvement measures are installed, the resulting OEE level attained would be measured and analysed and any improvements identified as a means of determining the efficacy of said improvements.
The OEE of a production process is obtained by measuring the individual levels of attainment in three discrete areas of production, again expressed as a percentage of the theoretical maximum for each area, namely;
3. Quality (or the proportion of good products produced as a percentage of the whole number produced)
These individual measures can be considered either on a machine-by-machine basis, by department, by site or as a business as a whole. However, all derivations will stem from productivity data collected from individual machines.
The OEE metric is calculated by simply multiplying together the three individual percentages for the three component elements to obtain an overall performance figure.
The OEE figure is a simple but very clear indication of just how efficiently a machine (or department or business) might be operating.
AssetManager has the functionality to allow customers to display whatever data they require from any of their installed applications on screens anywhere, either on their internal factory network or in remote locations (using the Internet). So for example, if you have say 5 machines in a department, any data from those machines can be displayed in any format. You might want to display production rates for each of the machines in adjacent bar charts, or the OEE attainment for the shift or the day or the product being manufactured. The possibilities are endless.
Tel: +44 (0) 1254 27 28 27
Fax: +44 (0) 1254 27 28 28
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