ASAP Factory Connect Process
DEFINE
Define Managements, Shop floor and Financial KPI’s
MEASURE
Capture Data from all data sources on the plant floor.
ANALYZE
Analyze the data using If and Why techniques.
IMPROVE
Improve organizational capabilities by taking effective measures
CONTROL
Sustain and further improve
Define – KPI’s
Manpower is used for analysis like trend analysis, Worst & best with respect to plant, Machine, Operator etc
Operational Reductions
Reduction in Downtime, Lot size, TAT & Operators
Operational Improvements
Improvement in Yield, OEE, Performance, and Capacity
Financial Reductions
Reduction in Cost of inefficiency, Production cost, Conversion cost & Opportunity loss
Manpower Utilization
Manpower is used for analysis like trend analysis, Worst & best with respect to plant, Machine, Operator etc.
Customer Delight
Reduced Customer TAT, Better customer fulfillment, reduced product cost
Inventory
Optimum utilization of Inventory. Reduced Wastage
Technology KPI’s
Reduction in manual data processing, Real time analysis, Remote Operations
Best Practices
Create lever for TPM, TQM, Six Sigma, Lean Manufacturing, KANBAN etc
Measure – Data Collection
Data from Devices
Get data from Meters, Sensors, VFD’s. Data like Power consumption, Chemical Consumption & Utility data
Operator Data
Operator will enter data manually like his attendance, Select the planning and Process variables
PLC/SCADA Data
Get production output, Wastages, MTTR, MTBF, Downtimes, OEE, Some process parameters
Mgmt System Data
Get data from energy systems, QMS/LIMS systems and Building management systems etc.
ERP Data
Get Planning data, Master data, Costing data, Stock data etc.
Analyze
Operator can see OEE of the machine, His own efficiency, Wastage of the machine, Power Consumption by Machine, Real time losses and Break down analysis
Operator
Shift In-charges or line managers can see Cycle time, OEE of the shift, Top reasons for downtime, Shift wastages, Trend of cost and Operator comparison
Shift In-charge
Plant Head can see overall production cost – Material cost, Power cost, Labour cost Etc. Relative Asset Utilization, Worst and Best performing Machines/ Section/ Operator, Cost of Wastages and Utilization
Plant Head
CXO’s can see Top/Worst plants, Trend analysis, Energy efficiency, Production outputs, Per unit cost of the products, WIP inventory etc.
CXO
Directors can see financial statements with respect to Plants, The most efficient plant, Critical highlighted areas and analysis vis a vis AOP.
Director
IMPROVE
SUSTAINED IMPROVEMENTS
