A plant floor data acquisition system is only as valuable as the information it provides from the raw data it collects. The ultimate goal of such a system is to become a reliable foundation for business performance. This is exactly what EIT™ can do for you: become your most trustworthy ally in daily decision-making and priority setting.
Soundly based on line design principles, the outcome of EIT™ development is strongly oriented toward the identification of efficiency loss root cause.
EIT™ does more than display metrics and key running parameters. It enables users to discover the issues that most negatively impact line output.
Thanks to EIT's accurate reporting, a 30-minute daily meeting is typically enough to target major production issues, take action and validate results. Information is also accessible remotely, in a timely manner and in a user-friendly format to suit various needs.
Hundreds of users from different industries have already used EIT™ to reduce operating costs incurred by low performance, unplanned downtime, waste, and poor quality. These are some of the benefits repeatedly mentioned by users:
- Yield improvement
- Quick R.O.I.
- Substantial reduction of unplanned downtime
- No labor wasted on completing log sheets
- Quality gains
- Major improvement of machine O.E.E. –Overall Equipment Effectiveness
Effectiveness
Besides the equipment, the operator is certainly one of the main assets of a production line. If he is knowledgeable and responsive enough, he can quickly handle machine stoppages to limit the negative impact on surrounding equipment and the line's output. To be efficient, the operator must master the machine's operation, observe specifications and be aware of the consequences of over-speed and stops. He must also have permanent access to the machine's status and output and to the line's flow.
In addition to being a real-time problem solver, the operator can provide a wealth of information. He must be able to comment on facts and events to ensure continuous learning and efficiency improvement.
Tasks & responsibilities
- Ensure the machine's proper operation
- Follow up on the machine's status
- Check production rate
- Fix any machine disruptions
- Comment on non-traceable faults and material issues
EIT Resources
- Display of real-time data, such as machine and line status, counts, rejects, throughput
- Details on downtime reasons
- Training tools, such as the line's historical replay (fast and slow motion)
- Shift reports
- Manual comments feature
Customer advantages
- Better response time
- Better compliance with specifications
- Enhancement of working methods
- Increased awareness of MTTR impact on OEE
- Improved communication among shifts
Effectiveness
One of the line manager's tasks is to make sure that his teams meet production deadlines.
Uncovering production issues is an ongoing responsibility. Pinpointing the issues that most impact the line's output is crucial. To be effective in his work, the line manager needs real-time data to set priorities and take action to promptly restore appropriate conditions.
Time is a luxury he cannot afford.
Tasks & responsibilities
- Assess the line's performance
- Conduct daily troubleshooting meetings
- Reduce recurring stoppages
- Analyze and solve the main sources of productivity losses
- Meet production deadlines and output
EIT Resources
- Root cause analysis
- OEE performance indicator
- Line overview & status
- Downtime reasons for each machine and the whole line
- Efficiency analysis
- Machine speed reports
- Shift reports
Customer advantages
- Elimination of production issues guesswork
- Quick identification of under-performing areas
- Improvement of work methods
- Line output increase
Effectiveness
The ultimate goal of a maintenance manager is to perform preventive rather than corrective maintenance, which is more beneficial to the line's output.
Maintaining machines in peak condition is a fundamental way to maximize production. Fostering maintenance improvements is an effective way of reducing inefficiencies due to breakdowns. To be able to maximize machine running time and performance, the maintenance manager must promote a productive approach to maintenance job planning.
Such methodology relies on closely tracking machine parameters and deviations to anticipate issues before they impact production.
Tasks & responsibilities
- Prevent machine breakdowns
- Analyze unplanned downtime causes
- Assess machine running time
- Plan maintenance jobs so as to minimize impact on production
- Validate results following repairs
EIT Resources
- Distribution of key running parameters (availability, running time, downtime duration, etc.) for machines
- Mean time to repair a machine
- Mean time between machine failures
- O.E.E. performance indicator
- Trending charts
- EIT Loss Reduction Module
Customer advantages
- Reduction of machine wear and tear
- Increase of machine running time
- Efficient tracking of performance guarantees
- Reduction of quality issues
- Identification of recurring problems
- Trending parameters for better awareness of upcoming production deficiencies
- Ability to practice and optimize preventive maintenance
Effectiveness
The production manager carefully plans the entire production process. He coordinates the resources and activities to ensure that production rates efficiently meet demand.
He must quickly assess and react to issues, track performance indicators and optimize every production phase, from quality and maintenance to line design and fine-tuning.
Tasks & responsibilities
- Assess performance
- Optimize the production process
- Target and resolve productivity losses
- Efficiently set up the production schedule
- Make strong cases for machine upgrades or replacements
EIT Resources
- SKU assessment
- Line summary
- Machine parameter analysis
- Root cause analysis (Audit)
- Efficiency trends
- Performance indicators: MTTR, MTBF, OEE
Customer advantages
- Line fine-tuning improvement
- Implementation of best practices
- Optimization of resources and assets
- Overall efficiency increase
Effectiveness
The main task of the plant manager is to run his facility as efficiently as possible by optimizing assets and resources and controlling costs. To organize, plan, supervise and manage the plant, he must have access to updated and reliable data covering the activities and performance of every production department.
In order to quickly assess production and detect major issues, the plant manager needs the support of a powerful information system, a real-time link to the plant floor.
Tasks & responsibilities
- Supervise plant operation
- Meet demand with output
- Make operations cost-effective
- Benchmark
- Budget
EIT Resources
- Efficiency analysis and trends
- O.E.E.
- Lines overview (EIT MAP module)
- Lines summary and downtime reasons
- Root cause analysis (Audit)
- SKU summary
Customer advantages
- Maximization of resources and assets
- Plant output increase
- Optimization of budget planning
- Effective decision-making
- Standardization of production procedures
Effectiveness
Much is at stake when supervising and managing many production facilities.
Closely monitoring production procedures, standardizing working methods, and promoting best practices usually result in a higher return on investment.
Managers can make strategic decisions, effectively respond to customer demands, gauge the impact of different options and better plan investments if they have the right information tools to monitor and report on individual equipment and overall plant performance.
Tasks & responsibilities
- Evaluate plant efficiency
- Control costs and losses
- Implement best practices
- Develop proactive working methods
- Benchmark
- Optimize investment
- Increase R.O.I.
EIT Resources
- Plant wide view (EIT MAP module)
- Company-wide view (EIT COMPARE module)
- OEE
- Loss tracking (EIT LOSS REDUCTION module)
Customer advantages
- Rapid overview of total plant output
- Effective discovery of major issues and patterns
- Better decision-making
- Optimization of capital expenditures
- Increased profitability
- Improvement of production flexibility
