edinn m2: the best tool for energy and productive improvement

edinn®M2

© edinn, 2004-2010. All information contained in this document is copyrighted.

Which cow is not profitable?

INTRODUCTION

Do you imagine seeing this?

INTRODUCTION

Management and control of work

• Production Scheduler• Stock and Resource Management • Production Data Collection • Maintenance Scheduler• Maintenance and Tool Management• Quality Assurance• Time and Activity Managment • Personnel’s access control• Productive and Energy Efficiency Improvement

Empowers your ERP (SAP, ORACLE, Microsoft, …) using international standards for connectivity.

INTRODUCTION

Automatic data capture

INTRODUCTION

And manual data capture.Always using availble spare time.

INTRODUCTION

INTRODUCTION

INTRODUCTION

Characteristics & Functions (Modules)

INTRODUCTION

EVERYTHING INTEGRATED

Production optimization Cost reduction Competitiveness improvement Productive efficiency Energy efficiency Quality improvement Production Management

INTRODUCTION

INDEX

OBJECTIVE

MEASURING

SPC

AUTOCONTROL

ENERGY EFFICIENCY

SUMMARY

OBJECTIVE

MEASURING

SPC

AUTOCONTROL

ENERGY EFFICIENCY

SUMMARY

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

OBJECTIVE

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

The world is becoming ever more competitive, because supply widely exceeds demand,and more countries are producing more and better.

Cost reduction, efficiency and quality improvement, reduction of energy consumption and environmental impact, etc. are essential for companies.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We need to increase our competitiveness”

An important part of the competitiveness depends on the production costs.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We need to reduce costs”

The best way to reduce costs is to produce more with the same productive resources.

So we can produce the same with less resources.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“Often we invest more money in a machine or process in order to

produce more, expecting results that we do not obtain”

We have increased our maximum production capacity but also our losses

have increased.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We need to produce more and we are thinking about

an investment in machinery”

There is always some level of wasted productivity, i.e. low efficiency. If we knew the exact detail of those losses, we could reduce them and produce

more while reducing costs.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We do not have enough information”

Because of the lack of objective and detailed information (automatically

taken from processes), our investment decisions could be suboptimal.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We need to reduce costs related to failures, stops,

etc.”

To increase production time, we need autocontrol: more secure and efficient maintenance (regulated by production)

and production regulated by procedures.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“Bad quality produces many productive losses”

A Statistical Process Control (SPC) and to know the reasons of “no quality”

would help us to improve this aspect.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“We need to improve”

It is very difficult to improve without objective, detailed and

automatically obtained information.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

To improve production we need:

1) Objective information (OEE, MTBF, MTTR, etc.), and

2) Standard tools and techniques: SPC, Autocontrol, Failure Prediction, etc.

1) Obtaining objective information in a factory is very difficult: there are many machines and persons, often it is a noisy place, usually every person has a different opinion on how to improve production, etc.

2) Standard tools and techniques (SPC, Autocontrol, etc.) are difficult to apply, not integrated and thus very expensive.

But…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

What is edinn® M2 ?

Edinn® M2 is the only system that automates manual processes, informs us by colours if we are operating efficient; and integrates the most important technical standards which are necessary for improvement.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

From a technical point of view, edinn® M2 is the only tool that is a MES or OES and a Manufacturing Ingelligence.

In addition, through sensors and processes (machines and operators), automatically 100% of productive losses are shown as well as the most important technical standards for improvement: OEE, SPC, Autocontrol, MTBF, MTTR, Enery Efficiency.

OBJETIVO MEDICIÓN SPC AUTOCONTROL ENERGÉTICA

RESUMEN

Makes your production more:

EFFICIENT

COMPETITIVE

COST-EFFECTIVE

ECOLOGICAL

PROFITABLEOBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

INTRODUCTION FUNCTIONS & CHARAC. EDINNM2 SALES

This is why many multinationals use edinn® M2 24h./every day.

In a simple and easy way…

• Normally installed within 1 or 2 weeks. *

• 100% configurable by the user.

• No need for programming.

• Flexible, adaptable and incredibly intuitive.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

* For 4 process installations

The objective of edinn® M2 is:

HELP TO IMPROVEPRODUCTION

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

In order to help to improve production… edinn® M2 is the only system that automatically monitors production processes and integrates necessary standards: OEE, SPC, Autocontrol, MTBF, MTTR, etc.The client decides which functionalities he wants to use: SPC, Autocontrol, MTBF, etc.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

MEASURING

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

And what is the first step to improve?

TO MEASURE

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“You cannot improve what is not controlled; you cannot conrol what is not measured; you cannot measure what is not defined."

W. Edwards DemingFather of the 3rd industrial revolution.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

You cannot improve anything that you cannot measure.

Statistically, only by measuring, we start to obtain improvements.

If we do not have the right information, investment decisions can be erroneous.

Because:OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

What is the best way to measure production? It should be standardized and independent of the sector and country in order to be comparable with other industries and countries. It should be directly linked to the profitability of the production process. It should be simple and easy to understand by anyone. It should include 100% of possible losses: availability (time), speed and quality.

It should be automatically captured and examinable at a glance.

On a long term basis, it should unattainable to reach the goal of 100%, in order to be on a real and continuous improvement.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

edinn® M2 solves this critical functionalityedinn® M2 solves this critical functionality

OEE

However, the OEE in a typical installation is NOT…

This way of measuring exists and it is called:

It is standardized and independent of the sector and country, in order to be comparable within industries. It can be linked directly to the economic profitability of the productive process. It is simple and easy to understand by anyone.

It includes 100% of possible losses: availability (time), speed and quality.

… Automatically captured and examinable at a glance.

(Overall Equipment Effectiveness)

Used by major manufacturing companies of the world: Toyota, FORD, Unilever, Ferro, Bonduelle, Metaldyne, Trelleborg, etc.

On a long term basis, it should unattainable to reach the goal of 100%, in order to be on a real and continuous improvement.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

A Available Time

CC Theoretical Production

DD Real Production MicrostopsSpeed lossMicrostopsSpeed loss

EE Real Production

FF Good ProductsScrapReworksScrapReworks

Total Operating Time Total Operating Time

Not scheduledfor producingNot scheduledfor producing

B Running Time

B/A x D/C x F/EAvailability QualitySpeed

OEE =

FailuresIdle TimesFailures

Idle Times

How is the OEE calculated?

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

“An OEE of 40% means that, of every 100 good products that could be produced, I am only producing 40.”

OEE AvailabilityAvailability SpeedSpeed QualityQuality

64% 91% 98%

57 %

How to interpret the OEE?

And it indicates where the losses are:

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

A manual calculation of the OEE requires:

Data entry forms. Training on how to maintain processes in order to obtain indicators. Manually inserted data. Entering collected data into a data base(5-10 min. each shift). Preparing reports for Management.

NOT RELIABLE, EXPENSIVE, IMPRECISE, etc.

AND It is still NOT captured automatically NOR examinable at a glance.

That the operator “remembers” what happened (easy) and exactly when (very difficult).

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

A manual calculation of the OEE requires:

Data entry forms. Training on how to maintain processes in order to obtain indicators. Manually inserted data. Entering collected data into a data base(5-10 min. each shift). Preparing reports for Management.

NOT RELIABLE, EXPENSIVE, IMPRECISE, etc.

That the operator “remembers” what happened (easy) and exactly when (very difficult).

Captures data automatically and can be examined at a glance.

edinn® M2

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Real time:Because the OEE is linked to profitability, edinn® M2 will show you via “green light” those production lines that are making money:

So you can focus on the lines that are not profitable, gaining valuable time…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

By clicking on the non profitable lines, you will see at one glance what happened: failures (number and type, time instances), low production speed, low quality, etc.

By clicking on the corresponding button you can see the exact details, second by second, product by product…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

All the information is captured by sensors at the process. When the system does not have the information, the operator must enter it.

But it will also show you aggregated information like never seen before…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Justification of stops is as easy as clicking on the correct time usage. Time usages are grouped and specific for each process.

Operators only perform 2 tasks: 1) justify pending stops 2) indicate product changes

By performing those tasks, all reports are automatically obtained…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

You will get to know 100% of the losses of production processes, automatically and precisely measured…

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

REPORT DE DETALLE DE PÉRDIDAS PRODUCTIVAS Min. %Tiempo total (min.) 7.200 100 No planificado (min.) 3 0,04 310-PLANIFICADAS\Ingeneria/Mejoras 3 100 Dependencias de línea (min.) 1 0,01 15F-PRENSA\CAMBIO MODELO\Falta de Preformas 1 100 No imputado (min.) 0 0 Producible (min.) 7.196 99,95 Esperas (min.) 1.988 27,63 305-OTROS\Parada fin de semana 1.522 76,54 14F-PRENSA\CAMBIO MODELO\Cambio de Modelo 146 7,35 301-OTROS\Tpm 100 5,05 32F-PRENSA\LIMPIEZA PRENSA\Limpieza tooling+Dedos+"V" 89 4,48 05H-HORNO SINTERIZADO\Descarga Horno 34 1,72 30F-PRENSA\CAMBIO TOOLING PRENSA\Cambio Punzon S. y Punzon I. 28 1,42 11F-PRENSA\CAMBIO TOOLING PRENSA\Cambio P. Superior 16 0,82 23F-PRENSA\LIMPIEZA PRENSA\Noyos y/u orificios 16 0,8 90F-PRENSA\CAMBIO MODELO\Ajuste puntos set press 14 0,68 24F-PRENSA\LIMPIEZA PRENSA\Punzones Sup. e Inf. 12 0,62 07R-ROBOT CARGADOR\Limpieza "V Block" 8 0,42 16F-PRENSA\VARIOS TOOLING PRENSA\Calentar punzones por parada 1 0,07 313-OTROS\Falta de bieleas en conveyor E 1 0,05 Paradas (min.) 106 1,47 15D-ROBOT DESCARGADOR\LUBRICANTE\Ajustes por Desajuste 25 23,65 19F-PRENSA\VARIOS TOOLING PRENSA\Retocar Punzón S. 14 13,44 FAI-PENDIENTE JUSTIFICAR 12 10,97 17F-PRENSA\VARIOS TOOLING PRENSA\Pegado biela en P.S. 11 10,1 20F-PRENSA\VARIOS TOOLING PRENSA\Retocar Punzón I. 10 9,64 M-Microparada 10 9,21 04C-CONVEYOR ENTRADA\Se engancha biela en guias 6 6 04R-ROBOT CARGADOR\Reajustar puntos Prog 6 5,3 01E-AVERIAS ELECTRICAS\Fallo eléctrico 4 3,85 01R-ROBOT CARGADOR\No coge biela del centrador 3 2,81 00F-PRENSA\Cambio parámetros 3 2,6 03C-CENTRADOR\Fallo scapament 3 2,43

… to obtain a complete analsyis down to the last unit produced.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Producción (min.) 5.102 70,9 0-Producción 5.102 100 Producción posible 36922 100 Pérdidas velocidad y microparadas 0 0 Producción rehecha 0 0 Producción desechada 58 0,16 2412S215-Caidas al suelo 3 5,17 2412S3040I-No llenado en la cabeza 3 5,17 2412S3040J-Inspeccion pzas. (Laboratorio) 8 13,79 2412S3040K-Centralidad 1 1,72 2412S3040Q-Rebaba incrustada 1 1,72 2412S3040V-Incrustación cerámica 1 1,72 2440S3040J-Inspeccion pzas. (Laboratorio) 33 56,9 2440S3040K-Centralidad 4 6,9 2440S3040M-Grietas 1 1,72 2440S3040V-Incrustación cerámica 3 5,17 Producción total 36.922 99,84 2412-2412 1.4L 6.011 16,28 2440-2440 1.6L 30.911 83,72

Detailed information about production, from all points of view.

MTBF and MTTR tables, prediction of the most probable failure to occur, associated documentation on the screen, etc.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

SPC

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

What is the most effective and standard tool to improve quality in

the industry?

SPC

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

SPC is based on:

* edinn® M2 SPC is approved by “tier 1” providers of the automobile sector.

• Measuring quality variables periodically, in order to control and improve the processes during production.

• Viewing control and histogram graphics to prevent declining of quality in processes.

But SPC is complex…

edinn® M2 integrates it in an automatic and simple way and includes everything necessary to satisfy the most demanding international quality standards *.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

To know whether a quality process variable is being controlled or progressively declining, its evolution history, its histogram, its control graphic, etc. are automatically generated.

As always, quality variables can be captured automatically or manually.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Use SPC in a simple way or benefit from the full complexity: capacity and CPK studies, automatic calculation of control limits, measurements and justifications of the process control, etc.

The most standard and powerful techniques, made easy and affordable.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

AUTOCONTROL

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Production cannot be totally efficient without

Autocontrol

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Autocontrol is based on:

* edinn® M2 Autocontrol is approved by “tier 1” providers of the automobile sector.

• Flexibility: maintenance follows real production, instead of calendar. Example: you send your car to the garage every 30.000 km, not every 3 months.• Procedures: maintenance and other tasks follow strict procedures, changing according to product, type of failure, etc.

But Autocontrol is complex…

edinn® M2 integrates Autocontrol in an easy and automatic way and includes everything necessary to satisfy the most demanding international quality standards*.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Buttons are blinking to indicate to the operator to perform maintenance. The colour and the order indicate critical items. Optionally, the operator introduces the results of performed tasks manually.

As always, the whole system is 100% configurable without programming.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

You will get to know inter-process time, results of maintenance tasks, special conditions, etc.

The edinn® M2 system changes the way in which production is “seen” and improved forever.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

ENERGY EFFICIENCY

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Energy efficiency is necessary in order to:

• Reduce costs and become more competitive

• Reduce environmental impacts

• Detect anomalies in the production, as they are normally seen as unexpected consumptions.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

The energy efficiency module of edinn® M2 is the only product available on the market that integrates: • Productive efficiency

• Consumption and cost analysis

• Analysis CO2

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Productive, energy, resources, costs and CO2 paths.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

SUMMARY

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

MEASURING Introduce your industry to a continuous improvement process based on real time knowledge of exact location of your losses.

SPC Improve quality of your processes by using the technology which is approved by the most demanding manufacturers of the world.

AUTOCONTROL Maintain machinery and processes in an efficient way, by linking machines to production and controlling procedures.

AND MUCH MORE • Additional functionality: easy to add with the help of our

open programming module (User Defined Logic).• Paper Free: no need of any more printed documents with

edinn® M2’s contextual Electronic Documentation System.• Continuous Information: edinn® M2 informs the operator of

the most probable failure to occur, provides feed back to ERP, etc.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Main characteristics of edinn® M2:

1. Useful in any industry and productive process: manual or automated.

2. 100% configurable, including capturing of signals and counters with no need for programming.

3. 100% standardized: OEE, MTBF, MTTR, SPC, OPC, etc. 4. Incredibly intuitive and easy to understand. 5. Exclusive functionalities that show the production process like

never seen before. 6. Operates with slow or noisy communication networks (on/ off-

line)7. Ideal to control a factory remotely.8. Allows the user or the system integrator to program any specific

need (UDL, User Defined Logic).9. Approved by “tier 1” providers of the automobile sector. 10.100% compatible with and essential for “lean” techniques.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Characteristics & Functions (Modules)

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

edinn® M2 is the only tool that provides all these functionalities integrated:

1. System to control and improve productive processes.2. Statistical Process Control (SPC).3. Maintenance regulated by production (Autocontrol).4. Production regulated by procedures (Autocontrol).5. Automatic collection of main production indicators (OEE,

MTBF, etc.) via electronic monitoring and generation of production Reports.

6. Control of non productive situations and quality defects via cameras.

7. Prediction and notification of most probable failures to occur by means of pattern analysis with neural networks.

8. Control of maximum times and autochanges of time usage and teams.

9. Control of operators and resources (activity ratios).10.Contextual launching of documents or applications: zero

printed papers.11.It allows to program anything on the programming module

(UDL).12.It is much more than a SCADA.

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

Architecture edinn® M2

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY

More information

Try the system

OBJECTIVE MEASURING SPC AUTOCONTROL ENERGY

SUMMARY