Automatic identification of losses

CHALLENGES/PROBLEMS

Lack of knowledge regarding major production losses
Lack of optimization opportunities
Lack of information on the magnitude of losses
Lack of uniform systematization and categorization of losses

SOLUTIONS

Uniform loss identification system for each machine, line, cell
Metrics to quickly locate the biggest problems
Visualization of the loss at the machine, such as downtime during a shift

PERSONS USING THE SOLUTION

Production Manager - sees how much time is wasted on the machine and how much more could be produced
Production Area Manager / Leader - sees what are the reasons for losses, e.g. late response of Maintenance to a reported failure
CIO Manager - knows where the main reasons for productivity loss are, analyzes data for different products, machines, brigades, production shifts, knows where to look for improvement
Team leaders and operators - see the downtime / loss on their own shift and strive to reduce these times to a minimum
Quality control - knows what quantities of production defects occur most often and how this has affected production efficiency

ADVANTAGES

"IoT system ready for Industry 4.0 transformation
Losses recorded automatically and in real time
Access to metrics, dashboards and charts via the web
Quick installation and system startup - 1 day
Proven solution - more than 30,000 installations worldwide
One-time cost (hardware + firmware + updates)

DESCRIPTION OF THE SOLUTION

LOSSES ON PRODUCTION

Categorizing productivity losses from an equipment perspective involves determining the condition of the machine/production. A solution based on the Vorne XL system allows you to group production states and assign a specific reason for the condition.

Unplanned downtime

Unplanned downtime is a loss of availability and a reduction in OEE. Examples of common causes of unplanned downtime include: machine failures, tool failures and unplanned maintenance, also lack of operators or materials. The Vorne XL dashboard will automatically capture and measure the duration of any unplanned downtime.

PLANNED STOPS

The biggest loss of machine availability time is usually changeovers. We also usually count maintenance, scheduled service, commissioning, quality control, cleaning, training and social breaks among the planned downtime.

PRODUCTION SLOWDOWN

Causes that slow down production are related to reduced productivity and quality. Examples of common causes of slowed production include sub-optimal changeovers, incorrect settings when running a new part, equipment that requires warm-up cycles, or equipment that inherently produces waste after startup.

IDLING AND MINOR STOPS

Idling and minor stops refer to the time when the machine stops for a short period of time (usually a minute or two), and the stop is resolved by the operator. Idling and minor stops represent loss of productivity.

REDUCED SPEED

Reduced speed takes into account the time the equipment runs slower than the ideal cycle time. Reduced speed is a loss of efficiency.

PROCESS FAILURES

Process defects account for defective parts produced during stable (established) production. This includes both scrapped parts and parts that can be reworked, since OEE measures quality from a first-pass productivity perspective. Process defects are a loss of quality.

ANALYSIS OF RECORDED LOSSES

The Vorne XL system enables advanced analysis of data collected from production. There are several metrics that include charts, indicators and summary tables. In addition, in each metric, we can separately select a built-in view with a data category and specify a time range.

METRIC "6 BIG LOSSES"

The metric automatically divides losses into categories of unplanned, planned, micro-downtime, slowed cycles, production defects and start-up defects. At a glance, you can see where the biggest production losses are.