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Kathy Barthelt
/ Categories: Infor LX & BPCS Tips, Infor LN & Baan Tips

Tip of the Week: 10 Ways to Succeed at an OEE Project Where 90% Fail

  1. Collect the requirements. Learn from everyone with the intent of developing a phased approach to implementing on your shop floor with OEE being Phase 1. 
  2. Create your list. Capture all of required functions, taking into account what the “output” of the system will be. What does the plant manager need to see in real-time? What KPI’s does each line need displayed in real-time? What reports are required?
  3. Insist Upon Real-time. In the moment data for the right OEE is the right approach. If it’s possible, collect the data automatically. Remember that real-time feedback to line operators results in an automatic increase in OEE.
  4. Evaluate your lines. Focus where production counts can be monitored automatically. If the data is in your PLC’s, can you get it out? OPC communication is the right way to go here. If not, the approach is to install a new dedicated PLC with sensors installed on each line.
  5. Find Your Data Points. If automatic production monitoring is not applicable, what will be your collection points and how will you collect the data?
  6. Calculate the Load. Determine how to load the “job” you’re reporting on into the OEE system. This will typically be the order/operation or the product from the ERP.
  7. Recognize Great Data. Do not accept “manual collection of data” as a viable approach because it produces false results and is labor-intensive.
  8. Be Tough. Evaluate systems based on OEE specificity to start and expandability to future phase functions as determined by your requirements. Plan to justify the OEE purchase on its own merits.
  9. Go Easy. Make sure the system is easy to implement. Software installation and configuration should take no more than 2 weeks.
  10. Be Simple. Put together a detailed but simple project plan indicating who will do what, how long it will take, and how you will monitor progress.
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Kathy Barthelt

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Tips:  LX | BPCS | M3

Poor performance indicators make for poor outcomes.

Companies today continue to tolerate and accept how labor and production information is recorded, and the reliability on that information is questionable. In addition to collecting labor and production information, there are many other pieces of information manually recorded from the shop floor.

A critical element of information for productivity throughput would be to examine how much time the work center or machine was actually up and running. Downtime is another critical element of data that is usually manually recorded along with a reason identifying what caused production to stop. If this information is not provided on a timely and accurate basis, then what good is it anyway? Forms are filled out, data may or may not be keyed to a spreadsheet, the forms are sorted and filed, but is anybody really looking at the information that was recorded? Think about the amount of time it takes to manage the manual collection of information from your shop floor. 

What would real time access to data mean to your organization?
The benefits:

  1. Real Time Production Visibility
  2. Reduced Paperwork Load
  3. Downtime and Scrap Visibility
  4. WIP Inventory Visibility
  5. Improve Efficiency, Capacity Utilization

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Happy New Year! January is always a great time to reflect on the prior year – what went well, and what didn’t. It is also the obvious time to plan for the coming year – what do I want to accomplish and how can I best achieve my goals?

As the saying goes, “you can’t improve what you can’t measure”, so if you haven’t already, it is time to start putting processes, procedures and programs in place within your company to measure how well each department is doing against their objectives. Start to analyze your numbers and publish them internally. Where are you at currently? Where do you want to be? Seeing both sets of numbers pushes employees to hit those targets. Do this now, and you’ll be seeing positive results before you know it!  

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