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Is it possible to improve OEE on the production line by 10-20% within only 12 weeks ? Can this improvement be sustained ? What’s more, can we assure continuous improvement and achievement of the OEE at the level higher than 85% within 2 years ? YES – it is possible and GrowTech developed tool from the Industry 4.0, which is enabling it – LossHuter.
Developing Operational Excellence Systems (OpEx) for the biggest companies in the World, like Philip Morris International, Bridgestone, Intersnack, Kraft Heinz, British American Tobacco, Amcor, Viohalco and being Subject Matter Expert of Procter & Gamble end-to-end OpEx system called Integrated Work System (IWS) I realized how important in Continuous Improvement journey is reliable and detailed data about losses in production processes. Companies undertake activities to eliminate losses, but in majority of cases, data that they use is not allowing them to identify real root causes of the problems or makes it difficult, as not all events are captured, like microstops (stops shorter than 10 min), there is many fake data in the systems, level of detail connected with data is insufficient to identify root cause, there are backets of events gathered under one name of the loss and quite frequently Top Losses are identified based on subjective information passed by people working on the line instead of real data from IT/OT systems.
The truth is that reliable operations starts from reliable data. You need to have information about all line events, especially those unplanned to be able to identify your Bottle Neck and Critical Losses. Quite frequently, short stops but occurring frequently, which are invisible to you, create the highest loss and frustration of Operators running the lines. Data must be cleaned from all fake events and have description allowing identification where loss occurred. Separate topic relates to the issues relating to useful presentation of this data – often there is no visibility, if there is any correlation between the losses when they occur one after the other or within short period of time, any relation with other events of the line, like planned activities – maintenance, cleaning, etc, relation to the way people are running the line, skills of the Operators or the time period, so if losses happen mainly during night or day shifts.
That inspired me to create a tool which will not only capture and clean the data, but will “connect the dots” and present Top Losses from all perspectives including correlation between them as well as between any other factors that may have influence on their occurrence – human, machine, processes, etc. This is how GrowTech has been created with the aim to deliver highly advanced loss analysis, based on real data, captured directly from production lines to speed up and improve quality of the process to get to the real root causes of losses and eliminate them permanently by application of Loss Shields – countermeasures to the losses.
GrowTech is made from passion to improve operations and get clients into Continuous Improvement journey. It breaks inability to improve by presenting Bottle Necks and Critical Losses of production processes at glance and giving you all info you need to get to the root causes of these losses and be able to eliminate them permanently – your operations will be at 85% OEE as a minimum in relatively short period time.
We offer comprehensive approach to deploy LossHunter App that allows for identification of real bottle necks in production processes and their permanent elimination, from installation of production line data capturing systems, via trainings in App daily usage, 24/7 support to advisory services in techniques of permanent loss elimination as well as development of Operational Excellence Systems assuring continuous improvement.
We select Pilot Line on which we install LossHunter App.
We connect to yours OT/IT systems where the data on events from production line, like planned & unplanned stops is stored. In case your systems do not store such data, we possess competences to install sensors allowing for such data collection
We train your Team on all functionalities of the LossHunter App and basic permanent loss elimination techniques
We jointly define the trial period for the LossHunter App on selected Pilot Line, which is the assessment period of App effectiveness and functionality
In case you are satisfied from LossHunter App functionalities, we define full deployment plan on all or selected production lines
We deliver Industry 4.0 & IoT solutions focused on continues improvement of performance of manufacturing entities by permanent elimination of production losses.
LossHunter – application that will identify loss related Bottle Necks in your production processes and will analyze them from all possible perspectives, “connecting the dots” for you to enable getting to the real root causes of your losses and eliminate them.
