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Industry 4 ( Factory connect)

ASAP Factory Connect Process

Factory

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

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

MEASURE
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

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

IMPROVE

SUSTAINED IMPROVEMENTS

ASAP