Improving Packaging Line Performance –Using the correct Data and Drill Down Analysis

Actionable Information II

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Data…Data…Data == Good Information

Excessive data – Lack of information The right data – with drill down analysis

X

Actionable Information

Actionable Information

1. What’s the right data to focus on the right areas?

Causal (loss to critical machine

Actual time

Machine stoppages

PDT/NOP

2. How can this be categorised in a useful way? And Why?

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What is Six Loss?

It would feel odd to drive a car without a dashboard…6 loss Analysis is like the dashboard, providing useful information for making decisions at different times in your journey. Example:– When there is an indication that you are low on fuel – you will fill it up – When the Revs are too high – you will change gear

OEE & Six Loss

Why use Six Loss?• Six Loss allows you to accurately pinpoint the area of focus that will impact

on the performance of the equipment’s output.

• To reduce each loss there is an improvement tool.

• All the Six Loss is doing is breaking down the equipment’s overall loss into six clear categories, to which, you can apply certain techniques to improve. It is what you do with this information makes the difference.

• Speed of Execution and intervention followed by monitoring is critical. Combine Six Loss data with using the right tools on the biggest loss and accelerate the speed of execution - This WILL improve the performance of your equipment.

• Many manufacturing plants spend a lot of time in measuring and recording data and don’t use most of it. Sometimes less is more!!!

This is a key part of your Manufacturing Strategy

The Six Loss Tool KitSix loss category OEE measure Reason for Loss Countermeasures

Planned downtime or external unplanned event

Availability

Changeovers Planned maintenance Material shortages Labour shortages

Planned Downtime Management 5S Workplace Organisation Pre-flight checks SMED

Breakdowns Availability Equipment failure Major component failure Unplanned maintenance

Kaizen Blitz PDCA Root cause analysis Asset Care / Planned / Prevent Maint

Minor stops Performance Fallen product Obstruction Blockages Misalignment

Cleaning 5S Workplace Organisation Adjustments / Centre Lining Line Minor stop audits

Speed loss Performance Running lower than rated speed Untrained operator not able to run at

nominal speed

Line Balance Optimisation Adjustments Training

Production rejects Quality Product out of specification Damaged product scrap

Six Sigma Error proofing Root Cause Analysis

Rejects on start up Quality

Product out of specification at start of run Scrap created before nominal running

after changeover Damaged product after planned

maintenance activity

Planned Downtime Management 5S Workplace Organisation Standard Operating Procedures Precision settings

Actionable Information

1. What’s the right data to focus on the right areas?

Causal (loss to critical machine

Actual time

Machine stoppages

PDT/NOP

2. How can this be categorised in a useful way? And Why?

Six loss data

Counter-measure for

each loss

3.How can we focus our efforts ?

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