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Factory Objectives. Value of Asset Management Strategies . Factory Objectives. Controlling Productivity. Disaster Recovery. Keeping Employees Safe. Improving Productivity of Indirect Labor. Avoiding Quality Issues. Reducing Commissioning Time & Cost.

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factory objectives
Factory Objectives
  • Value of Asset Management Strategies
factory objectives2
Factory Objectives

Controlling Productivity

Disaster Recovery

Keeping Employees Safe

Improving Productivity of Indirect Labor

Avoiding Quality Issues

Reducing Commissioning Time & Cost

Complying With Regulations Requiring Audit Trails

what concerns you
What concerns you…

Controlling Productivity

Disaster Recovery

Keeping Employees Safe

Improving Productivity of Indirect Labor

Avoiding Quality Issues

Reducing Commissioning Time & Cost

Complying With Regulations Requiring Audit Trails

controlling productivity
Controlling Productivity
  • Case: Home Care Products Manufacturer
    • Production constraints forced us to keep the line running. As a result, when the there was a problem, maintenance inserted a “patch” to the asset configuration, which is only designed to temporarily fix the problem.
  • Consequence:
    • Eventually the “patch” was not enough to keep the line running. The original problem became a major problem. The line was down for hours before they could get it back up and running.
  • Solution:
    • Automatically tracking all changes to asset configurations and knowing who made the change, allows the manager to find out the reason for the change and can schedule work to fix the problem when there is less of an impact.
  • Benefits:
    • Lower production cost and better overall delivery times.
    • Provide reliable change management to efficiently manage assets.
disaster recovery
Disaster Recovery
  • Case: Pet Food Manufacturer
    • Computer maintenance lost programs on several key assets. In spite of manually saving programs on a central server, they ended up using a very old version made by the OEM of the machine.
  • Consequences:
    • Hours of downtime and lost production to be made up with overtime.
    • Extra cost of indirect labor for remaking the asset configurations.
  • Solution:
    • By managing asset configuration versions automatically in a central repository and by automatically backing them up, no program is lost. As well, through version control, everyone knows which program to use immediately.
  • Benefits:
    • Save production cost and delivery time issues by always knowing which program is the right version.
    • Provide confidence in the process and controller program for the engineering and maintenance teams.
avoiding quality issues
Avoiding Quality Issues
  • Case: Olive Oil Manufacturer
    • An annual maintenance review showed that some sensors needed to be replaced. After several weeks, customers started to complain about poorly sealed bottles. After investigation, someone discovered the faulty wiring of the sensor, which resulted in the poorly sealed bottles.
  • Consequences:
    • Reimbursement for the affected customers causing the company additional expense.
    • Several weeks’ production stock was fully inspected at additional costs, in order to identify poorly sealed bottles.
  • Solution:
    • By regularly collecting diagnostics of devices and displaying the status and troubleshooting information to the maintenance team makes them immediately aware of the problem. This information includes details on how to fix the problem, and in many instances, the maintenance team can take action before the problem actually occurs, thereby avoiding downtime.
  • Benefits:
    • Line stays up and running to maintain continuous production and to potentially avoid an incident in the first place.
    • More effective use of the maintenance team.
    • Scrap reduction.
regulation audit trail issues
Regulation & Audit Trail Issues
  • Case: Pharmaceutical Company
    • It is a requirement to maintain an audit trail of their production, including actions performed on assets. In order to comply with this requirement, the company maintains a manual process whereby all engineers are required to complete documentation for every change.
  • Consequences:
    • Inconsistent quality of change documentation.
    • They already had troubles due to non tracked changes in spite of the internal manual procedure.
  • Solution:
    • By automatically tracking each change, the company can be sure it has not missed any changes automatically. Engineers no longer have to manually prepare the change documentation.
  • Benefits:
    • Certain compliance with audit requirements.
    • Prevent mistakes being made by unskilled or untrained individuals.
indirect labor issues
Indirect Labor Issues
  • Case: Oil & Gas Distribution Business
    • Periodically an engineer is tasked with taking machine analysis readings at several locations for preventive maintenance. It takes almost a week to get the readings from each location, and then the analysis is performed and decisions made about the data.
  • Consequences:
    • Waste of a valuable resource who provides no added value compared to what this skilled person could do for improving productivity and maintaining equipment.
  • Solutions:
    • By automatically gathering and analyzing (against standards) the readings from the machinery, the engineer is used for more valuable tasks.
  • Benefits:
    • Increase productivity of human capital
    • Better analysis and consistent decisions about data
    • Decrease cost of indirect labor
indirect labor issues10
Indirect Labor Issues
  • Case: Assembly Line
    • We put in a computer maintenance management system in several years ago to track work and spare part usage. Unfortunately, when the line stops, no one wants to take any time to enter a work order and afterwards no one seems to identify what the root cause was and what was used to fix it.
  • Consequences:
    • Inconsistent root cause and spare parts usage data.
    • Management can not make needed decisions about maintenance because data is unreliable.
  • Solutions:
    • By automatically gathering work orders from the machinery directly, no time is wasted by maintenance to get to the actual problem. Since the work orders exist, it is much easier to track root cause and usage.
  • Benefits:
    • Increase productivity of human capital
    • Better analysis and consistent decisions about data
    • Decrease cost of indirect labor
    • Less spare parts inventory
commissioning issues
Commissioning Issues
  • Case: Consumer Product Manufacturer
    • During commissioning of a line, one team would write over another teams valuable changes.
  • Consequences:
    • Commissioning took considerably longer.
    • Project cost increased & delayed releasing new product to market.
  • Solutions:
    • By allocating individual access rights to assets and configuration tool functions, they are able to contain one team to certain tasks and devices avoiding rework.
    • By tracking changes, the two teams were able to understand what and why changes were made and by who. As well, the most recent program was always available, as well as a complete version history, in the event an inadvertent change was made.
  • Benefits:
    • Reduce time to market and costs with quicker commissioning due to collaboration between the teams.
employee safety
Employee Safety
  • Case: Metal Manufacturer
    • Someone performed several configuration changes to assets associated with a production machine. Changes were intended to be temporary, and consequently were not documented. Because the changes were not to be permanent, testing to insure that no security or safety risks existed did not take place.
  • Consequences:
    • An operator had serious injuries.
  • Solutions:
    • By tracking changes, the customer now is able to check regularly what changes, if any, were performed by who and when. It is now possible to discover the changes and insure they are compliant with security rules and if they are not permanent, check if they were removed.
  • Benefits:
    • Prevent injuries to employees, contractors, visitors, and other in the plant.
rsmacc solving plant floor problems
RSMACC solving plant floor problems…

Controlling Productivity

Disaster Recovery

Keeping Employees Safe

Improving Productivity of Indirect Labor

Avoiding Quality Issues

Reducing Commissioning Time & Cost

Complying With Regulations Requiring Audit Trails

in the booth
In the booth…
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