The Platform on which to build the Lean Enterprise

Improving Improving Efficiency Efficiency

Real time Real time Performance Performance ManagementManagement

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Finbar Gallagher: BioFounder of Fraysen Systems,

20 years experience developing systems which deliver information critical to successful Lean Manufacturing.

Hewlett Packard Medical Devices

Hewlett Packard Inkjet Supplies

Tellabs Inc.

Bachelors of Science in Electronic Engineering from Dublin University

Master of Science in Systems Engineering from Boston University.

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Agenda

Crisis

Roadblock

Solution

Requirements

Results

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The “Burning Platform”

Hourly Costs

US . . . . . . . . $21.83

Ireland . . . . . $18.80

China . . . . . . . $0.92

“China is revolutionizing the relative prices of labour, capital, goods and assets in a way that

has never happened so quickly before” – The Economist, July 28, 2005

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CrisisOEE%

Time

30

50

70

100

Lean with traditional IT (ERP,

MES, SCADA) & manual methods

Don’t have information to

understand issues in time to make a

difference

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Information is Roadblock

Too LateBlack HolesDisassociated

Can’t get the Big Picture

!!

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But…

Problems can be solved

Not rocket science

Resolution typically application of common sense

Perennial challenge is lack of information which is:

Complete

Specific

Trusted, and

Timely

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Solution

Seconds

Hours

Shifts

Days

Weeks

Minutes

Mach

ines

People

Product

Proce

ss

Mate

rial

SCADA

Real-time PerformanceManagement Systems

MES

ERP

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Real-Time Performance Management Systems

RPM Systems enable Manufacturers to RPM Systems enable Manufacturers to understandunderstand and and controlcontrol the the

interactioninteraction between people, equipment, between people, equipment, and product, and so manage the and product, and so manage the

operation to its maximum capacityoperation to its maximum capacity

Real-time: That which is relevant to the real-world operations of a company – “in time”, “on time”, or “right time”

Managing Automation, 2004

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With RPM, manufacturers can:

Sense the environment more intelligently

Predict and Prevent problems before they occur

Identify and correct problems as they occur

Business Process Change“Real time information causes you to reassess your course of action”

Gartner Group, 2005

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To Succeed, You Must Have

In Real-timeWith Full History

Integrated View of Whole Process

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Challenges

Access to all equipment / information

Equipment state mapping

Process mapping

Uncovering true management process

Agreeing common metrics

Cultural change

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Requirements MapRequirement

High Medium Low

Scalable: Distributed Architecture

Centralized Architecture

No High Level Architecture

Adaptable:

Configurable Product

“Simplified” Programming Tools: Visual

Basic

Classical Programming

Tools

Complete:

Direct collection from ALL

data sources

Direct collection from

some data sources: OPC

Reliant on Intermediate

Systems: MES, etc

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Requirements MapRequirement

High Medium Low

Real time:

Real-time Presentati

on from Real-Time

Data

Historical Reports

from Real-time Data

Reliant on Batch Level

System Sources: MES, etc

Integrated:

Integrated Process

Information Model

Single, Uniform Schema

Multiple databases /

schemas

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Results

“Immediately we had a very detailed view of uptime”. Within 1 week, identified and eliminated 4th highest cause of downtime.

Live data is presented in an objective manner. This exposes and prioritises problems for the team. “before it was hearsay – now we now have factual information to guide us”

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Results

“This is a much more efficient way to get accurate information and make better decisions”.

Enabled greater automation through higher machine reliability

Real time information directs Supervisors to where problems are: focus quickly and fix issues before they affect numbers.

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Summary

The tools now exist for discrete manufacturers to:

Get timely, integrated information,

Solve problems, and

Achieve World Class competitiveness:

Real-time Performance Management