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Executing the fundamentals is critical to success. For process management, those fundamentals include well designed and implemented plant floor data collection, management and analytics to support decision making. With these systems in place, the company can establish operational excellence. Without them long term success is impossible. In this presentation, Bill Palmer reviews how the core practices of process management and analytics begin in operations and mature to become key elements of enterprise management. He draws upon his consulting experience to provide case studies illustrating what works effectively in practice. To view webcast - http://www.nwasoft.com/resources/webinars/creating-effective-data-driven-decision-making-systems-production-quality-and-cos The presenter: Bill Palmer is Assistant Professor of Electromechanical Engineering Technology at Murray State University and the principal of Palmer Consulting. For 22 years he has designed and deployed quality information systems for manufacturing clients and taught manufacturers how to apply the principles of SPC and continuous improvement to plant floor operations and corporate management.
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It’s all about leverage
How does management get leverage on the system.
Push Harder?
Work Harder?
Push Harder?
Work Smarter?
Push Harder?
Change the System!
How Does This Play Out in the Plant?
Better Operator Tools
Islands of Information
And, at the end of the day?
Computerized Information is better, BUT…..
Data Automation Shows the Process, But…
Floor
Manager View
Operator Stuck in the Same Spot
Skills and Tools for Effective Management
Floor Manager View
Boxplots for Mulitple Processes
Management Needs to Understand the System
1. Convince employees that data is important. Show them you are really using it!! This may be the only best way to minimizing gaming of data.
2. Visualize the system with graphical representations of process data.
3. Understand the system with statistical knowledge.
4. Have the ability to instantly compare and study the necessary data.
William Palmer
Case – Managing Co-Producer Conformance
ACME
H G F E D
C B A
1
2
3
4
5
William Palmer
Track ODs With SPC Database
ACME
C B
A
DB
ACME QA
William Palmer
Co-Producer Period Flavor Report
William Palmer
Period Moisture Report
William Palmer
Capability Trending
William Palmer
One Period Process Stability
William Palmer
The Leverage Point
Set Up Production Information System.
Analytics and Rationalized Data Sources
Manager View Floor
Relational Database
Statistical Visualization and Analysis Software
Statistical Visualization and Analysis Software
Common SPC Analytics Mistake
Assumption: What’s important is the operator seeing the real time process. Mistake: Choosing software based on whether or not the operator will be able to see the real time process. NEWS FLASH: ALL SPC software does that!
A Common Start-Up Mistake
Mistake: Setting up data sources that focus primarily on the needs of the floor user. Problem: The Manager Summary Reporting tools may be “too inconvenient” to use, and therefore will be underutilized. Quite often it is convenient to set up systems to look at a specific process. The big ROI down the road might be from comparing processes.
ERP
Barriers to Managerial Understanding
Manager View
Statistical Visualization and Analysis Software
Statistical Visualization and Analysis Software
Excel
CSV
Access
Rationalize What You Have
Manager View
Statistical Visualization and Analysis Software
Statistical Visualization and Analysis Software
Excel
CSV
Access ERP
Centralized Database
Manager View
Statistical Visualization and Analysis Software
Statistical Visualization and Analysis Software
Centralized Database
Advantage: Data is relatively easy to query. Data that is easy to query, gets queried. Disadvantage: All data must go through the Central Database, so, either all data must be written there, or special utilities must be developed to route data to the Central Database. Disadvantage: You may be limited to the reporting technology that was developed for the Central Database, thereby reducing reporting options.
Decentralized Data Source
Advantage: Data is also relatively easy to query. Data that is easy to query, gets queried.
Advantage: Data or reference information remains in already convenient locations. Disadvantage: Some work needs to be done to relate the data sources to minimize barriers to reporting. *Advantage: Easier to take advantage of reporting advances created by 3rd party vendors.
3rd Party Reporting Can Help
SQL Server Quality
DB Controls DB
Other DB
ERP Supplier Other Dbs
Combine Databases for Leverage
SQL Server Quality
DB Controls DB
Other DB
ERP Supplier Other Dbs
