ProductivityProductivity

Maximizing Asset Utilization

ProductivityProductivity

Agenda

1. Concepts & Case Studies→Evaluate potential to add value to your operations

2. Metrics→Evaluate potential to enhance your Dashboard

3. MxMax™ Productivity →Evaluate potential to more effectively unite functions and levels into

high performance team

Asset UtilizationAsset Utilization• Productivity “Tool” with maximum impact on the business

• Shows what to work on, value to business• Justifies initiatives & secures management support• Reveals true production performance / production impact• Improves delivery performance, increases capacity• Reduces waste & quality losses, optimizes costs

• OEE is a component of Asset Utilization(Overall Equipment Effectiveness)

• OAU: correlates directly to capacity and gross profit(Operating Asset Utilization)

Large specialty chemicals manufacturer: 4 year result• All plants – average capacity increase >15% Globally

(>30% Asia Pacific)

Continuous lubricants plant: 1 year result• $4.6MM increase in GP (75% improvement)• 33% reduction in Mechanical Integrity incidents

Batch reactions plant: 9 month result• Capacity increased 24% (3 month rolling average)

Asset UtilizationAsset UtilizationCase StudiesCase Studies

Asset Utilization – the ValueAsset Utilization – the Value

Eliminate Losses

True Definition of ReliabilityMake what, when, & quantity wanted

Operating Asset Utilization

True Definition of ReliabilityMake what, when, & quantity wanted

Operating Asset Utilization

Capacity / GP

Process Capability & Stability

Capacity Innovation

Decrease Constraints

Schedule Fulfillment

Efficiency

Lowest Cost Posture

Process Impact

Measure

Business Results

Operating Asset Utilization Capacity Impact

Asset Utilization Sales Impact

Capacity Utilization Available Capacity

Overall Equipment Effectiveness Performance vs. Plan

Validated ProductionYieldQuality RateAvailability ratePerformance rate% Operational Losses% Reliability & Maintenance Losses

MetricsMetrics

POWERFUL TOOL FOR POWERFUL TOOL FOR ASSET UTILIZATION AND OEEASSET UTILIZATION AND OEE

Productivity

Available instantly to all functions, levels, and authorized global locationsTrue enabler for the high performance team

Major Work Processes

Type of Issue

Equi

pm ent

Details

Equi

pm

ent

DEEP ANALYSIS OFDEEP ANALYSIS OFSYSTEMIC AND SPECIFIC ISSUESSYSTEMIC AND SPECIFIC ISSUES

Real-time Information

TRUSTED PRODUCTION METRICSTRUSTED PRODUCTION METRICS

On-demand: eliminates data handling and report preparation

CONSISTENT MANAGEMENT CONSISTENT MANAGEMENT REPORTINGREPORTING

EFFICIENT DATA ENTRYEFFICIENT DATA ENTRYElectronic LogbookCaptures Workforce KnowledgeEngages Operators in Continuous Improvement

Average data entry time < 5 minutesAverage data entry time < 5 minutes

Operator ToolsOperator Tools

Operators see performanceTheir shift or batch

Prior shifts or batches

Operators see performanceTheir shift or batch

Prior shifts or batches

• Customize terminology & setup at each plant / process

• Full Local Language capability

• Exclusive visibility to each person’s area of responsibility

Fosters Local OwnershipFosters Local Ownership

损失

• Reports in global language versus local language

• Leverage improvements across sites global visibility

• Global terminology, Custom tri-level loss categories

Fosters Global LeverageFosters Global Leverage .

Same Graph: viewed by non-Local PersonSame Graph: viewed by non-Local Person

ROBUST PLATFORMROBUST PLATFORM STATE OF THE ART WEB HOSTING ON THE STATE OF THE ART WEB HOSTING ON THE

AMAZON CLOUDAMAZON CLOUDReliable – Amazon EC2 offers a highly reliable environment where replacement instances can be rapidly and predictably commissioned. The service runs within Amazon’s proven network infrastructure and datacenters. The Amazon EC2 Service Level Agreement commitment is 99.95% availability.Secure – Amazon Web Services(AWS) delivers high availability and dependability.

•SAS70•Secure Design Principles•Physical Security•Redundant multiple physical location storage•DDoS, MITM, IP Spoofing, Port Scanning, Packet sniffing security

More on Security

ProductivityProductivityEliminate Production LossesEliminate Production Losses

without IT Headaches!without IT Headaches!

No IT setup and maintenance•Web provided service•Access with standard browser•Version always current