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TOP TEN PROVEN TIPS TO
MAXIMIZE UPTIME AND BOOST PERFORMANCE
Smart Solutions Powered by TrakSYS™
Top Ten Proven Tips to Maximize Uptime and Boost Performance Page 1
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So, your company is not yet performing at world-class levels when it comes to packaging. You’re
not alone—most companies aren’t. You’re probably interested in “leaning out” your operations,
but don’t have the budget or time for a full-blown lean implementation.
Doing nothing is not a good option, given the pressures exerted by your own corporate
management team to continue boosting profits—in spite of higher energy costs, higher materials
costs, higher labor costs, and any other challenges posed by your particular market. Well, there
is no reason you cannot adopt many of the same methods and techniques that world-class
companies used to become world class. And because you aren’t taking early-adopter risks, you
can bring about similar levels of improvement more quickly and at a much lower cost.
If that sounds too easy, then take a look at the following “Top Ten Proven Tips,” which distill what
is working today at companies that are the leaders in terms of Lean Six Sigma implementations,
operational excellence and world-class performance.
TIP 1: SET OVERALL IMPROVEMENT GOALS
You have at least three times more potential to improve than you currently think is possible! For
example, many companies that started their Lean initiatives several years ago continue to
achieve significant gains in productivity. Don’t cripple your efforts before you even get started by
setting less-than-ambitious goals that will only provide a marginal benefit to the business.
How do you set appropriate goals? Measure current performance—then get out and benchmark
against best-in-class and your peers. Many companies have increased the productivity of their
lines by 20 percent or more!
TIP 2: REVIEW CURRENT KPIS
It is difficult to improve that which cannot be measured accurately. Yet many companies are
guilty of producing charts for “historical reasons”, where the data basis is unclear, data accuracy
is questionable, and the data are charted but not actually used to drive improvement. How many
times have we seen the infamous “line efficiency” metric with calculated values exceeding 100
percent? Too many!
This is always a red flag, and likely indicates target values are based on average performance
instead of best demonstrated rate or theoretical rates. Critical to any productivity improvement
initiative are a relatively small number of Key Performance Indicators (KPIs) that can be measured
accurately, easily understood, and directly aligned with your greater business objectives.
Has your company clearly defined these key metrics in a document so everyone has a common
understanding of how they should be measured? How accurate is the raw data? What is
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excluded? Have theoretical rates been determined properly? These types of questions will ensure
you are using metrics that matter!
TIP 3: IMPLEMENT OEE
Overall Equipment Effectiveness (OEE) is a worthy standard for driving productivity
improvement. Defined as the product of availability, performance, and quality, OEE breaks your
losses into three easily understandable components—each of which requires different types of
solutions to improve. Unlike the traditional plant “efficiency” metric which often is designed
around typical output, OEE is designed to show all the key losses that could be improved upon to
boost productivity and capacity.
TIP 4: SET LINE-SPECIFIC IMPROVEMENT OBJECTIVES
World-class OEE for discrete operations such as packaging is defined as:
Key Indicator World Class
Availability 90.00%
Performance 90.00%
Quality 99.90%
OEE 85.00%
Some lines and operations in your plant might be running at far less than world-class OEE. Many
food and beverage operations that begin an OEE initiative are starting in the 40 to 50 percentile
range. No matter what is your starting point, OEE improvement targets should be specific by line
or operation, and should include separate improvement targets for availability, performance, and
quality, as shown in the following example:
2014 OEE Improvement Goals for Line 1
Timeline Availability Performance Quality OEE
Current State 60.00% 75.00% 98.00% 44.00%
Year-End Target 75.00% 80.00% 98.10% 59.00%
Gain (Points) 15 5 0.1 15
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TIP 5: GAIN MANAGEMENT’S COMMITMENT
To reap big benefits—and most plants should be aiming for a multi-million dollar gain—you will
need to get the management team on board. Their help will be needed to support organizational
culture changes, to provide funding, to provide reward systems, and to keep the organization
focused on the effort in spite of all the other priorities competing for their time. Management
also must accept the notion of exposing the plant’s weaknesses so those weaknesses can be
understood and improvements can be made.
Once management sees how OEE improvement relates directly to the overall business objectives
and what a significant financial impact it can have, they will sponsor the initiative. Take the
example of a frozen foods company with net sales of $156 million and operating at a baseline
OEE of 50 percent. Because OEE is proportional to output, if the company increases its OEE by
just 5 points, its net sales capability will increase by 10 percent, or $15.6 million. If the company
has demand for the additional product, based on a 78 percent cost of products sold, then this
will boost profits by 68 percent! If the demand isn’t there, then the plant can cut back on the
amount of overtime or number of shifts to achieve a hard dollar savings.
Figure 1- TrakSYS™ Web Reporting Portal Allows Role-Based Reports of Key Performance Indicators
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TIP 6: AUTOMATE KPI DATA COLLECTION
If you don’t know about it, you can’t fix it. Many plants are stymied by a lack of accurate
information that would allow them to understand why they are stuck at current productivity
levels. Or there are so many opportunities it is difficult to know what problems to attack first.
Fortunately, real-time performance management software is now available that allows
companies to automatically collect accurate, real-time performance data from various sources.
This allows complete characterization of line performance through continuous tracking of OEE
and other KPIs in real time, and the relation of these to every equipment failure—including
frustrating short stops that might just be a few seconds in duration.
TIP 7: IMPLEMENT A ROLE-BASED WEB DASHBOARD
Once you have automated data collection, you need a simple real-time method to share that
information with everyone in the plant who is involved in the improvement effort. Look for RPM
systems, such as TrakSYS™ from Parsec Automation Corp., that provide a role-based Web
dashboard as seen in Figure 1, which offers extraordinarily quick and easy access to reports
relating to each person’s specific job function.
Reports should provide one-click drill down so users can intuitively dig more deeply into an area
of interest without having to navigate through a complex menu structure.
TIP 8: ENGAGE ASSOCIATES DIRECTLY
Imagine playing a soccer game, but in this variant of soccer, scoring is so complex the referees do
not announce the score until the game is over. This is the way many manufacturing plants
operate today! It is critical to get the plant floor associates and technicians directly involved in
the productivity improvement efforts. One way to do this is with a plant floor client application
that provides the operators with the real-time “score” as they are running. This application also
can be used to collect additional information from operators related to running the lines; for
example, when operators stop the line for a changeover or sanitation.
TIP 9: IDENTIFY CHAMPIONS AND KEY IMPROVEMENT TECHNIQUES
How many times does an initiative fizzle because the company cannot maintain focus? It is
recommended that companies give one or more champions the responsibility for running the
improvement program, and educating the plant team so that everyone understands the
objectives and the tools provided to reach the goals.
Many tools from Lean Six Sigma are being applied successfully to improve the availability,
performance, and quality of production operations. Examples include SMED and 5S for
changeover time reduction, Theory of Constraints to ensure a focus on improving operations that
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will generate a positive impact, and processes such as DMAIC and 5 Why to analyze problems
and develop solutions.
TIP 10: SHARE SUCCESSES
The most successful improvement initiatives have a broad foundation. Involve the entire plant
team by soliciting ideas for process and procedural improvements (in some plants, “waiting” is
the number one cause of downtime) and have a multi-disciplinary team review and respond to
every suggestion from the plant floor.
Figure 2- TrakSYS™ Provides Analytics and Tools That Enable Champions to Drive Continuous Improvement
Regardless of Methodology
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Implement the best ideas and publicize the successes. Provide a rewards system that
acknowledges the contributions of individuals, as well as line teams that succeed in reaching their
improvement goals. Recognition and rewards can help transform the plant floor culture to one
that is truly high performing.
GOING FORWARD
These 10 tips have all been successfully applied in many manufacturing plants and work best
when they are all used as part of a comprehensive improvement program.
Don’t be one of the many manufacturing operations teams that are “too busy” chasing their tails
to achieve real improvement. It takes a significant effort to break out of the “tail-chasing” mode
of operation and begin a journey toward continuous structured improvement. This journey will
provide many rewards—financial and personal—for those who choose to follow this path.
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ABOUT PARSEC
Parsec Automation Corp. (Parsec) is the developer of TrakSYS™, the leading real-time operations and
performance management software. Manufacturing companies worldwide rely on Parsec for flexible and
configurable tools to execute manufacturing operations across the value stream more effectively.
Without production disruption, TrakSYS™ helps manufacturers to significantly improve asset utilization
and efficiency, increase capacity with no new capital equipment, reduce production costs, decrease lead
time, and improve profitability. With measurable ROI, TrakSYS™ delivers the bottom-line results that
manufacturing companies are looking for. For more information about Parsec, please visit the corporate
web site at www.parsec-corp.com.
TrakSYS™ is a flexible, scalable, and powerful software application that is specifically designed to improve
the management and execution of manufacturing operations. TrakSYS™ is designed to measure, control,
and improve process capability and performance throughout the value stream regardless of
infrastructure. TrakSYS™ makes it possible to define KPIs specific to each area of operations for meaningful
insight into constraints and their root causes. This makes performance an enterprise initiative instead of
an isolated endeavor. By prioritizing bottlenecks by impact, TrakSYS™ helps to streamline continuous
improvement efforts to get the best ROI in the shortest time possible, and TrakSYS™ makes it possible to
reduce the lead time throughout the value stream.
TrakSYS™ is Designed to Effectively Help Manage Manufacturing Operations and
Their Performance in Real Time
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Top Ten Proven Tips to Maximize Uptime and Boost Performance
If your food and beverage operations are not yet performing at world-class levels, you’re not alone—most companies’ operations aren’t. There is no reason you cannot adopt many of the same methods and techniques that world-class companies used to become world class.
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