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Manufacturing Intelligence
The Production Floor
Departments Workers Work Cells
Operations Machines Manual Work
The Planned Production Process
The Planned Routing in Priority
Production Reporting Screen
Discovering the Actual Production Process
With
Disco
Example Deliverables
Some Possible Deliverables
A process map of the executed production processes Conformance Checking
► Deviations
Performance Analysis ► Machines
► Operators
► Idle times
► Bottlenecks
Focused analysis of: ► Breakdowns
► Rework
► Rejected
► Parts
Comparison of workers performance Analyzing transfer of parts from the production floor to a subcontractor*.
* Published in a separate presentation
The data Source
The production reports data are exported from the ERP (or MES)
The mandatory data
The Data in Disco
The Production data are configured and imported to Disco for process discovery
The Process in Reality
The actual process is animated based on the production data To view the animation press here.
Work orders starting the process
A Bottle Neck
Operation Date
Indication of work loads
The Actual Process Model
A visual map displays the flow of the process based on the sequence of operations Boxes represent the operations Arcs display the sequence of the operations performed on work orders Numbers at the arcs and in the boxes represent frequencies of operations and paths The thickness of the arcs and the coloring of the boxes visually support these numbers.
Analysis of Operations
Revealing Deviations from Routing
For some work orders, the process starts with different operations then defined in the routing (circled in red)
Locating the Slow Work Orders
The Performance filter is used to retrieve the desired work orders by duration
The Model of the Slow Work Orders
Numbers in the boxes represent the mean duration of the operations Numbers at the arcs represent the mean idle time between operations. The thickness of the arcs and the coloring of the operations visually support these numbers.
Statistics About Products in the Slow Work Orders
Demonstrating the Bottlenecks with Animation
Analysis of Work Cells
The Process Model by Work Cells
Boxes represent the work cells and the operations done in them Arcs display the paths of the work orders among the work cells Numbers in the boxes represent work orders in work cells Numbers at the arcs represent work orders transferred between work cells The thickness of the arcs and the coloring of the boxes visually support these numbers.
Locating the Longest Idle Times
The Performance filter is used to retrieve the work cells with the longest idle times between operations
Longest Idle Times in Work Cells
The numbers at the arcs represent the longest durations of idle time between operations in the work cells
The yellow arrow represents a repeating operation in the same work cell.
Statistics About Work cells
A statistics display about the work cells with the long idle time
Statistics About Operations
A statistics display about the operations in the work cells with the long idle time
Analysis of Breakdowns
Statistics About Work cells with Reported Breakdowns
Statistics About Breakdown Reasons
Analysis by a Selected Breakdown Reason
The Impact of a Breakdown on a Selected Part
The operation with the ellipse was reported as a breakdown The red arrow points at a delay in the process (compared to one indicated by the green
arrow)
With Breakdown Without Breakdown
Analysis of Rejected & Rework
Statistics About Rejected Parts
Statistics About Rejected Quantities
Statistics About the Operations Involved
Statistics About the Workers Involved
Comparing Operations & Workers
With rejected parts
Without Rejected parts
A Comparison of Processes
With Rejected parts Without Rejected parts
Retrieving Work Orders with Rework
A Comparison of Processes
With Rework Without Rework
Additional Analysis
Comparing Production Processes of 3 Parts
Comparing Different Machines for a Selected Part
Machine 4 Machine 5
Comparing Fast and Slow Work orders of a Selected Part
Fast Work Orders Slow Work Orders
For further info & demo please contact:
Dafna Levy
Email: dafnal@nool.co.il
Phone: +972 (0)54-6881739
Intelligent Process Management
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