dashboards for data based decisions · unit manager, machining dashboards for data based ......
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Jenő Csanaki
Opel Szentgotthard Ltd.
Unit manager, Machining
Dashboards for data based
decisions
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Content
About OPEL Szentgotthard
Planning - Tool set - Execution
• Business environment
• Data – Measure - KPI
• Data processing, forums
• Reports
Results
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13
9
11
10
4
5
6
3
1
1. Family1 engine plant22,500 m2
630,000 unit per year
3. Cylinder-head plant15,500 m2
625,000 unit per year
13. Transmission Remanufacturing1,100 m2
11,700 unit per year
12 2
7
8
2. Flex engine plant65,426 m2
645,000 unit per year
14
Layout & capacity
4-5. Offices6. Outbound Transportation Hall7. Warehouse8. Energy centre9. Truck gate10. Personal Entrance 211. Social Building12. Main Entrance / Offices13. Reman14. Knowledge Center
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55
Chevrolet Aveo/Sonic Chevrolet Cruze
Chevrolet TraxOpel Corsa Opel Astra NB
Opel Zafira Opel Insignia Opel Mokka X
Cars with Family1engines
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Opel Insignia
Chevrolet Cruze Chevrolet Malibu Opel Adam Opel Cascada
Opel Mokka X
Opel Zafira Opel Astra Chevrolet Equinox
Cars with Flex engines
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CH2
New Plant/Extension
Existing
Plant
MDE/SG
E (Alu)280 K/Y
CBL3CBL1
SGE /
MDE
180 K/Y
CHM1
He
ad
Su
b AssyAssy1
MGE/SGE
285 K/Y (+ 85 K/Y)
AssyAssy2
MDE
275 K/Y (+95 K/Y)
Hot Test
Logistic
SGE
MDE
(Alu)180 K/Y
CBL2
SGE /
MDE
280 K/Y
CHM2
SGE
MGE275 K/Y
CRK2CRK1
MDE275 K/Y
He
ad
Su
b
Coolant BlockIndirect store
Co
ola
nt
cra
nk
Co
ola
nt
he
ad
MGE
(Cast
Iron)100 K/Y
Fam1
MGE
100 K/Y
Flex machining lines & capacity
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Example: Cylinder block machining line 3
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tdcbafThroughput ,...,,,,
As a function…
a: # of characteristics,b: # of machines,c: # of spindles(stations),d: fd(share of characteristics between operations),e: fe(conveyance),
f: ff(cycle time),g: fg(measurings),h: fh(planned, unplanned tool change),i: fi(interventions by operators),j: fj(breakdown),k: fk(impact of other machines, gantries, conveyors, adapters,…),l: fl(types, type changes),
…
Throughput- Planning
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Process
Measure
KPI
Layeredreporting
Visualisation
Component
production
Produced
parts
Uptime
Data Information
Manufacturing process visualisation
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Processes KPIs
Energy &Utilities
Maintenance
IT systemsSupply chain&
Logistics
Supplier quality
Uptime
SAT=Output/(RunningTime+Downtime) [JPH]
SAT: Standalone Throughput
Uptime=NetOutput/(ScheduledHours/CycleTimepurch) [%]
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UptimeBottleneck
Regular auto-identification
Quantity losses
Downtime, duration & frequency
Cycle timeBy operation
By type
During type change
ScrapMaterial
Production
TouchRework
Suspect
Uptime Cost
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DATA - DATA PROCESSING – REPORTS
Requirements
• Proper data quality in time
• One data once entered
• Tracking changes in time (target changes)
• Be capable to
• aggregate
• identically defined measures
• Fast response
• Layered reports
• Shared BI
• Sharing
Data management, BI
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„Business Intelligence is a set of methodologies, processes, architectures, and technologies
that transform raw data into meaningful and useful information used to enable more
effective strategic, tactical, and operational insights and decision-making.” Evelson, Boris (21/11/2008)
Business intelligence and OLAP
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Machines
Time
Product
type
Multidimensional data structure
OLAP cube
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PMC
TL, SL
Flexnet
CMM
report
Qs-StatOLAP
Tabular
Data sources, systems
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Reports
Special
reportsOLAP
Cubes
Data
Warehouse
Measures, KPIs, BIData
Shared BIDashboards
ShiftreportsOLTP
Database
Browser
ME MySQLData
Collection
Scheduling Flexnet PASPMC
FACS(Flex Assy)
Schneider Energy Mgmt
AVL(Hottest)
MGO
System structure
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Report structure
Frequency
Production area
Shared BI
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Web based reports
Shared BI – new
report
Weekly report
Production
dashboard
Reporting examplesShared BI – new report
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Shift
Reports Weekly
report
Monthly
report
PMCDaily production
meeting TIP
Weekly production
meeting
Weekly production
meetingTIP
TIP
Cost management
reviewBPD review
Uptime action
plan update
LRP, CIP plan
Daily
Weekly
Monthly
>Monthly,
Annual
BN (SAT) ranking
Manuf Staff Mtg,
PPRMTIP: Throughput Improvement Process
BN: Bottleneck
SAT: Standalone Throughput=Output /
(RunningTime+Downtime)
LRP: Loss Reduction Project
Cost
report
Systematic forums & reports
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PM&C
bottleneck
(SAT) ranking
WEB interface
shiftly, manual supported by PM&C on-line
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Web based reports
Shared BI – new
report
Weekly report
Production
dashboard
Reporting examplesWeb based
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Shared BI, database connections
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Daily reports
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Web based reports
Shared BI – new
report
Weekly report
Production
dashboard
Reporting examplesProduction dashboard
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Weekly reports
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Web based reports
Shared BI – new
report
Weekly report
Production
dashboard
Reporting examplesWeekly report
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Monthly reports
Action plans
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Other reports
Time from operator call to
maintenance arrival
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Uptime improvement result
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Cost developement 2015 vs. 2016
Scrap cost
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THANK YOU FOR
YOUR ATTENTION!