KPIs, OEE – Key Performance Indicators and Overall Equipment Effectiveness.
To provide practical and real metrics to Lean Manufacturing methodologies is crucial for the analysis phase in the virtuous cycle of continuous improvement of product quality, for the availability of facilities and for the production process performance. In addition, having a more effective efficiency indicators values, allows to make decisions in the initial moments of a deviation or to anticipate the causes of a performance drop.
En las áreas, las líneas y los módulos de fabricación discreta objeto de la mejora continua, en que pueden conocer y registrar en tiempo real los siguientes parámetros:
In areas, lines and discrete manufacturing modules, that are subject to continuous improvement, it can be known and recordered in real time the following parameters:
A. The time in production or stopped.
B. The production rate.
C. The counting of units produced with the expected quality and the rejected ones.
D. The status of the production order from launch to closing.
E. The plannification for production orders. We can automatically calculate, within a specified period of time, a series of key performance indicators (KPIs) to highlight the following:
Efficiency, Overall equipment effectiveness – OEE
Productivity, Total Effective equipment performance – TEEP
MTBF / MTTR: Mean Time Between Failures and Mean Time to Repair.
Lead time: time between the launch and closing of an order with the released product.
Also in the areas and units of batch manufacturing process, it can be defined the model of “perfect batch” for the formulation of a prescription for a particular product, collecting significant information during the phases of the process: the actual consumption of materials, the use of process units, the execution times of productive and non-productive phase, and deviations from the expected quality.
To record and analyze the causes of variation of KPIs by the Pareto diagram and SPC, involves the interaction with human operators in the moment just happens the incidence of the line (or the deviation from “perfect batch”), in order to request information on equipment stops (or phase), speed reductions equipment, out-of-quality products and the hanging production orders.
Set an initially performance management methodology for linking, prioritize and standardize the KPIs in the context of other operation and financial metrics. It allows to compare the results between different facilities, production plants and the improvements investments made.
LMS – Human Resource Management System (Labor Management System)
The human resource management system supports day to day by:
Effective human resources planning – internal and external – considering the availability and qualifications of employees.
The management of schedules and shifts depending on the production orders program
The employee’s compensation by productivity.
Registration and calculation of performance data related to wages.
Access control on the doors and entrances of buildings and plants of the company.
APC – Advanced Process Control
In order to improve the capture of staff working time, it is important to record the time of presence and absence of employees.
On the basis of the access control system, it is possible to monitor the presence of a group or an operator in the workplace assigned, in a turn or a production order determined. With these data we can obtain specific ratios of productivity and personnel costs.
Productivity ratios obtained may relate directly to equipment efficiency ratios and manufacturing lines, in case of implementing a cross solution of resource efficiency management (REM).