manufacturing conference workshop 3 - oee and energy
DESCRIPTION
OEE, overall equipment effectiveness, energy monitor, workshopTRANSCRIPT
John Roberts
Managing Director, Operations, Idhammar Systems
Energy Efficiency and OEE
15th November 2012
©Copyright 2012 Idhammar Systems Limited
Pan-industrial Customers
KEEPING INDUSTRY MOVING AND IMPROVING...
KEEPING INDUSTRY MOVING AND IMPROVING...
Proven Track Record in the Food Industry
Workshop• What is OEE and how does it influence energy
usage?• What information is available now?• Linking Energy usage to production and
inefficiencies• Improvement Opportunities• Payback
KEEPING INDUSTRY MOVING AND IMPROVING...
What is OEE and how does it influence energy usage?• A standard index of manufacturing efficiency• Based on...
• Utilisation• Line availability• Manufacturing performance• Product quality
• Why use it....• Compare performance within industrial sectors• Measure of continuous improvement on a line or within a site• Highlight inefficiencies
• Drive improvements in efficiency
KEEPING INDUSTRY MOVING AND IMPROVING...
Why measure OEE?
KEEPING INDUSTRY MOVING AND IMPROVING...
• Facilitate Continuous Improvement• Identify efficiency losses (and opportunities for
improvement) in detail...• Minor stops• Slow running• Material scheduling failures• Quality issues• Line and machine downtime• ‘No Production Required’ windows
Availability 65%
Performance 67%
Quality 92%
OEE 40% 60% Opportunity for Improvement
BreakDown
No Staff
Minor Stops
SlowRuns
Rejects
Scheduled Production Time
168 hour week
OEE: the basics
NoMateri
als
No Production Plan
KEEPING INDUSTRY MOVING AND IMPROVING...
Gathering the data• Automated metering
• Meter reference• Date & time• Meter reading
• Manual• Area / Line / Asset • Date• Meter reading
KEEPING INDUSTRY MOVING AND IMPROVING...
Monitoring Energy
KEEPING INDUSTRY MOVING AND IMPROVING...
• Energy consultants have offered this type of service for years
• They can provide• Energy consumption by site• Sometimes by zone/area• Graphs over time
• Accurate analysis can be difficult due to a shortage of meters
Standard Approach: Limited Meters
Zone A Zone B Zone C480
485
490
495
500
505
510
Zone A - C, Week 01 - 2012
kWh
KEEPING INDUSTRY MOVING AND IMPROVING...
Too few meters: accurate analysis is restricted.Zone B has used the most electricity, but where and why?Has Zone B run for a longer period?
Better: Energy Consumption by Line
Line 01 Line 02 Line 03 Line 04 Line 050
100200300400500600700
Lines 01 - 05, Week 01 - 2012
kWh
KEEPING INDUSTRY MOVING AND IMPROVING...
More meters: we can compare electricity usage between production lines.But we still can’t tell if Line 04 has run for a longer period.
Even Better: Energy Consumption by Asset
Filler Capper Boxmaker0
100
200
300
400
500
Line 01 - Assets, Week 01 - 2012
kWh
KEEPING INDUSTRY MOVING AND IMPROVING...
More meters: the filler has consumed the most electricityBut we still don’t know how many products have been made.
Full Picture: Energy and Product Produced
KEEPING INDUSTRY MOVING AND IMPROVING...
Base kWh load Performance blip Higher than base load, production has finished and staff forgot to turn off the glue unit
Energy Usage with Drill down to Assets
KEEPING INDUSTRY MOVING AND IMPROVING...
Energy Usage Over Time with Units Produced
KEEPING INDUSTRY MOVING AND IMPROVING...
Gathering the Data
KEEPING INDUSTRY MOVING AND IMPROVING...
Current Transformers
Pulse Meters for Gas & Water• OEE already provides:
• Asset Structure• Running Hours• Products Made• Stoppage Events• Productivity• Utilisation
• Energy Data feeds will provide:• Energy Consumed• Energy per Production unit
by time• Energy usage comparisons:
• Line / Shift / Product
Opportunities
KEEPING INDUSTRY MOVING AND IMPROVING...
• Can we turn heaters on later?• Can we install more efficient heaters?• Can the plant run faster for the same energy
usage?• Can any equipment be powered down during a
breakdown or Production stoppage?• Can we automate power shutdown?• Can we use OEE analysis improve in these areas:
• Minor stops• Slow running• Material scheduling failures• Quality issues• Line and machine downtime• ‘No Production Required’ windows
ROI: Bakery
KEEPING INDUSTRY MOVING AND IMPROVING...
Return on Investment per production line High volume High waste Low product unit price High energy cost Significant quality monitoring Manual data capture
Some opportunities for manpower reduction
Costs
OEE system £ 4,000
Internal manpower allocation at start up
£ 1,000
Total £ 5,000
Potential Savings per Day Value now
1% improvement
Product sales value £ 24,000
£ 240
Daily throughput 80000
Sales revenue per unit £ 0.30
Cost of Waste £ 1,500
£ 15
Manpower £ 2,500
£ 25
Energy £ 7,000
£ 70
Quality management £ 100
£ 10
Total £ 360
Return on Investment 14Days
ROI: Spirit Bottler
KEEPING INDUSTRY MOVING AND IMPROVING...
Costs
OEE system £ 15,000
Internal manpower allocation £ 1,500
Total £ 16,500
Potential Savings per Day Value now
1% improvement
Product sales value £ 28,000
£ 280
Daily throughput 7000
Sales revenue per unit £ 4.00
Cost of Waste £ -
£ -
Manpower £ -
£ -
Energy £ -
£ -
Quality management £ -
£ -
Total £ 280
Return on Investment 59Days
Return on Investment per line High volume Low waste Moderate product unit price Steady energy usage Automated quality monitoring
Automated data capture with manual input
Some opportunities for manpower reduction
ROI: Tractor Factory
KEEPING INDUSTRY MOVING AND IMPROVING...
Return on Investment for the site Low volume Low waste High product unit price Steady energy usage Significant quality monitoring
Automated data capture with manual input
Few opportunities for manpower reduction
Costs
OEE system £ 100,000
Internal manpower allocation £ 20,000
Total £ 120,000
Potential Savings per Day Value now
0.01% improvement
Product sales value £ 12,000,000
£ 12,000
Daily throughput 120
Sales revenue per unit £ 100,000
Cost of Waste £ -
£ -
Manpower £ -
£ -
Energy £ -
£ -
Quality management £ -
£ -
Total £ 12,000
Return on Investment 10Days
Summing Up
KEEPING INDUSTRY MOVING AND IMPROVING...
• The drive to increase energy efficiency will continue
• Better management of energy usage will be required
• Better management will require better information• Good information is provided by more & higher
quality data• Restrict energy usage to what is required to
PRODUCE• OEE systems with Energy Monitoring will deliver
the information required