MES visualisation tools offer speedy payback

Edited by the Engineeringtalk editorial team Apr 3, 2006

Just one month after implementing the Ampla Downtime reporting system, an individual ABC plant achieved a 50% reduction in stoppages.

Although purists may argue information systems are unnecessary for lean manufacturing or six sigma improvement initiatives, leading manufacturers are achieving strong results by using real-time technology systems and manufacturing execution systems (MES) in conjunction with continuous improvement initiatives.

A recent study by McKinsey demonstrates that companies using information technology to complement continuous improvement initiatives are achieving better results than companies using only a single approach.

Leading management practices alone resulted in an average 8% increase in productivity compared with a baseline measurement.

Companies that add IT tools to improvement initiatives accomplished a 20% increase in productivity.

Although manual processes achieve good results, the addition of automation and real-time data achieves better results.

"Next generation MES systems are providing manufacturers with powerful tools to attain real-time visibility into the plant floor".

"This allows companies to make faster decisions with more accurate data and often take proactive steps before problems impact productivity", comments Martin Filz, Managing Director for Citect in Europe.

A recent example of how an MES solution increased gains from a continuous improvement initiative can be found at Adelaide Brighton Cement (ABC).

ABC is the only national cement supplier in Australia, and employs over 1300 staff.

ABC adopted a continuous process improvement plan that focused on its plants and operators.

Using the plan, ABC identified unscheduled system downtime as a significant contributor to increased production costs against raw material output.

The company began gathering downtime data using a number of sources: control room log sheets, Microsoft Access databases, Excel spreadsheets, SPC control charts and CitectScada reports.

The information was analysed and reported during weekly performance meetings.

Using Pareto charts, ABC was able to identify the root cause for the top ten plant stoppages.

Unfortunately using a manual system required engineers to devote three days each month gathering data.

Analysis was performed after the event, preventing the ability to take immediate measures.

ABC implemented a Citect Ampla Downtime reporting system to measure asset utilisation, stoppage information and trend data.

The system now automated data collection and provides robust visualisation tools, such as Pareto charts, to provide operators with a more detailed picture of stoppages.

During each shift, the operators enter their interpretation using customised pick lists or entering the cause.

Management then performs analysis on a daily and weekly basis to identify trends and abnormal occurrences for prioritised action.

The entire system was developed in less than two months.

Just one month after implementing the Ampla Downtime reporting system, an individual ABC plant achieved a 50% reduction in stoppages demonstrating that adding MES visualisation tools can significantly enhance continuous improvement initiatives.