The system for line efficiency measuring is our new product which could assist you in constant monitoring of production lines in a modern way aligned with the principles of contemporary management of production line efficiency. A team of engineers has been involved in the development of the project, and all of them have invested their knowledge and experience, in the process technics, production analysis, pc technology, industrial electronic and automation, into a unique product. The system has been already implemented into several production plants in Serbia and neighboring countries, please note these are production plants owned by regional leaders in the food industry branch. LEM is naturally suitable as well for other industry branches beside the food industry, namely, it is favorable for all plants which have in their goals set to track production line efficiency. The scope of the system includes installation of measuring-editorial equipment on the lines, connecting it into a unique network, and software installation that provides the possibility for remote monitoring of the production processes. The system possesses high level of flexibility related to the adjustments in line with certain client’s specific demands. Comprehensive and systematic analysis of the production process makes it possible for the management to optimize the production processes and by it significantly reduce production costs. In the scope of the system for tracking and reporting, and per the client’s wishes, there is the possibility to install also scoreboard principle for tracking operational results of production lines in actual time. This system represents an extraordinary concept related to visual management and it provides special impression of organization and arrangements within one system. In the practical production conditions the constant feedback regarding the efficiency of the work spontaneously awakens the desire for achieving better results and it creates competitive and winning spirit.
Technical solution
Central terminal has been designed in line with the industrial needs, in the stainless-steel cabinet with high degree of IP protection. Software is User friendly with a very intuitive handling principle. Under the assumption of elementary PC knowledge, training of operators can be executed in a few hours and the system is in use and operational from the day of terminal installation.
User interface
Each system in one factory or in one production area possesses a software for data viewing and reporting – Viewer, that is WEB based and available for everyone within the company. In this way, the entire management team is constantly familiarized with the actual status in the production and it is possible as well to perform historical data analysis.
Some examples of reports can be seen here:
Selected period is a report which contains the structure of all times specific for calculation of the efficiency on all the production lines. There is as well option for exporting data into excel sheet. Furthermore, this type of report offers overview of all stoppages both in graph and table form for selected line. Table form includes option of drop-down menu to view data in more details.
Column diagram
PARETO in a picturesque way indicates the duration of some stoppages on a monthly or MTD level, which provides faster detection of most frequent causes of stoppages. Furthermore, this places the focus on the most significant tasks which lead to results achievement in a most efficient way.
Time line diagram
Indicates time diagram for the production process of certain products for each production day. This type of diagram provides the number of changeovers on a production line, and therefore it can be used as a tool for optimization and improvement in planning processes.
Stoppage Analysis
Offers a table view for all stoppages, with all the details in a defined period. This report also has the possibility to export data into an excel sheet which is favorable for further analyzing.
Filtering KPIs per users/products/time
provides the view of predefined efficiency indicators for production lines and according to the requested search criteria. This type of reports offers the possibility as well, to export data into excel sheets, which are favorable for further analysis. KPI reporting per operators is quite useful for measuring work performance and creating proper development plans for the operators, while KPI measuring per products can represent additional source of information during defining of the product price.
Impact on productivity
Impact on quality
It is well known that even beside all methods used for quality control some nonconformities might occur, especially during mass production. It is very important to determine the cause of nonconformity to prevent repetition of same issues. By analyzing historical data which are stored in LEM system, very often reasons for occurrence of nonconformities can be pinpointed.
Interface with other systems
Data are being recorded into SQL base, therefore they can be read by other informational systems. With significant flexibility, it can successfully support requested measuring and reporting which are necessary for establishing LEAN methodology.
System availability
Along with the choice of quality materials and standard components which we tried to embed into the system, to enable reliable operation and efficient maintenance, one of important project tasks, which we placed before us, has been to create a system that will be available and reasonably priced for everyone wanting to work in line production.