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High Performance (PR and CI) Introduction Training Pack

High Performance (PR and CI) Introduction Training Pack. Process Reliability. Process Reliability (PR) is a performance measure similar to OEE. Used in McCormick’s US Industrial Group. PR is the % of time we run our Lines, at a specified rate. Net Production PR =

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High Performance (PR and CI) Introduction Training Pack

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  1. High Performance (PR and CI) Introduction Training Pack

  2. Process Reliability • Process Reliability (PR) is a performance measure similar to OEE. • Used in McCormick’s US Industrial Group. • PR is the % of time we run our Lines, at a specified rate.

  3. Net Production PR = Scheduled Time * Target Rate PR Calculation

  4. Net Production Total Product produced on the Line minus Scrap and Rework. N.B. Poor quality product discovered after QA testing is included (unlike in OEE). This is done through rework models.

  5. Scheduled Time • The time used for production, or required for any business activity which would make the system unable to produce • Ask yourself……… • “Would this activity cause downtime if the Line was full 24/7?” • Examples - Breaks, Intrusive maintenance, Intrusive cleaning, Breakdowns, unplanned product outages, Changeovers, Washouts. • There are exclusions • Trials • Scheduled McCormick Meetings e.g. Team Briefs, Break-outs.

  6. Target Rate Rate of the Value Added Constraint for that Line and SKU E.g. kg/min, sachets/min

  7. CM 71 PR Example • For Example – C&O CM71: • Packer 1 runs CM71 for an 8 hour shift, all breaks are due to be covered. At the end of the shift the line processed 15,000 kg of saleable product. Net Production PR = Scheduled Time * Target Rate PR = 15,000 Kg 480 minutes * 68 kg/min PR = 46%

  8. Simple Rules • Changeovers are included in Scheduled Time for the SKU that has just run. • Only McCormick meetings are excluded (Team Briefs, Break-Outs, General Meetings). • Rework taken off Net Production based on rework model e.g. 20% rework, Production = 10,000kg, rework = 2000kg.

  9. Process Reliability (PR) and “The Pie” PR = Time spent making Good Product at the Target Rate Rate Loss = small stoppages + non-value added activities Downtime = Time the Line is not running

  10. Best Demonstrated PR • Best Demonstrated is the “Best Ever” straight run (over 4 hours) of a product on record. • Best Demonstrated targets will answer the question “Have I had a good day?” • We also need to ask: “What can I do to run this product like this again?”

  11. Best Demonstrated Pies • Building a highly visible, motivational way of communicating shift performance and performance expectations.. Best Demonstrated Performance Actual Performance Best Demonstrated Performance Actual Performance

  12. Focus on the important issues Define  Target big improvements Break down into small chunks Analyse & Improve Measure Leverage Control Restore Find the real reason for the problem Fix any defects Re-apply solutions elsewhere in Factory Track how we are doing before, during and after Make sure the changes stick forever Do the Improvements Re-establish standards CI Process

  13. PR: The new OEE • PR and “Best Demonstrated” will drive High Performance. • PR will help us focus on the Constraint rather than the whole production line. • PR is simply the % of time we are (on average) at the Target Rate. • “Did we have a good day?” is easily answered by comparing to Best Demonstrated. • PR will point us in the right direction for CI activities.

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