Via the application launched today, manufacturers can more easily access real-time and historical packaging line data, targeting key availability, performance and quality losses, as well as bottlenecks for the line overall. Implementable in days, it empowers companies not only to take the right corrective action quickly, but also to continuously monitor line efficiency KPIs (key performance indicators) and implement improvements. With CoLOS® OEE, gains of 10-15% on critical lines are achievable.
Tackling high downtime, low performance and poor quality is a priority for all manufacturers. One way to increase efficiency is to measure and improve OEE (overall equipment effectiveness), a standard method measuring manufacturing productivity composed of 3 KPIs: Availability, Performance and Quality. Unfortunately, most existing OEE solutions are expensive and time-consuming to implement, as they require custom programming or the expertise to undertake complicated configuration. CoLOS OEE, by contrast, is an easy to set up, off-the-shelf application that is still 100% configurable, and provides the insights needed to improve efficiency within days of purchase. The tool is also scalable – suitable for a multi-step approach from one line to full-site deployment.
Key challenge measuring and improving OEE
Typical OEE rates before continuous improvement program implementation are 50-60%. While best-in-class plants achieve 85% OEE rates, many struggle to improve their figures as they do not have easy, timely and comprehensive access to the information they need to calculate, let alone track, it effectively.
A quicker, easier way to calculate OEE and optimize line efficiency
Feedback from customers trialing the software in its development phases, has been positive. “We can now make better data-driven decisions to implement line improvements,” says Todd Mondry, Vice President of Engineering and Operations, Red River Commodities. “CoLOS OEE has proved so effective that we’re planning to deploy it across all our facilities. In fact, I’m regularly asked by plants for updates on when they can deploy it at their location.”
Because it is part of the market-leading CoLOS information management system, CoLOS OEE collects data from existing Markem-Imaje coders, or any OPC-enabled packaging line devices, at two points along the line, with no need for extra hardware or communications.
By analyzing the data collected at these points, CoLOS automatically calculates the OEE KPIs which are defined as the following ratios:
• Availability: real versus planned production time
• Performance: real versus theoretical maximum line rate
• Quality: good versus total products produced
These KPIs are displayed on real-time dashboards, helping operators ensure their lines produce the maximum number of high-quality products, taking into account planned downtime and stops.
If a line stops unexpectedly, for example, the counters will pause. This is reflected on the dashboards, alerting operators who can fix the issue immediately. Once the problem has been identified and rectified, the operator can select the relevant reason on the user interface, to facilitate further analysis. Alternatively, if the feature is enabled, CoLOS OEE can get the error code data automatically from the relevant packaging line devices.
Providing the insights needed to identify the root causes of inefficiency
CoLOS OEE provides a variety of historical reports so managers have the facts they need to enhance productivity permanently by prioritizing and eliminating the top reasons for downtime, performance and quality losses. Quickly and continuously they can identify trends and fix the root cause of issues to achieve greater efficiency gains of up to 10-15%.
Used with Markem-Imaje’s other Packaging Intelligence solutions, efficiency can be improved even further.
“You can’t improve what you don’t measure and taking data-driven decisions reduces risk while substantially increasing chances of a successful outcome,” observes Mark Hathaway, CoLOS Software Product Manager, Markem-Imaje. “Manually collecting the information needed to implement the right changes, however, is time consuming and subject to human error. Custom automation improves accuracy but can take years to develop. Our launch opens the door to any company ?small, medium or large, with or without the funds or time for a long development process? who wants to improve their OEE,” adds Hathaway. “Our tool is easy to use and install, plus it provides the detailed data needed to drive big increases in production efficiency.”
For more information please visit: https://www.markem-imaje.com/colos-oee.