OEE, overall equipment effectiveness, energy monitor, workshop

1. Energy Efficiency and OEE
John Roberts
Managing Director, Operations, Idhammar Systems
15th November 2012
©Copyright 2012 Idhammar Systems Limited

2. Pan-industrial Customers
KEEPING INDUSTRY MOVING AND IMPROVING...

3. Proven Track Record in the Food
Industry
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4. Workshop
• What is OEE and how does it influence energy
usage?
• What information is available now?
• Linking Energy usage to production and
inefficiencies
• Improvement Opportunities
• Payback
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5. What is OEE and how does it influence
energy usage?
• A standard index of manufacturing efficiency
• Based on...
• Utilisation
• Line availability
• Manufacturing performance
• Product quality
• Why use it....
• Compare performance within industrial sectors
• Measure of continuous improvement on a line or within a site
• Highlight inefficiencies
• Drive improvements in efficiency
KEEPING INDUSTRY MOVING AND IMPROVING...

6. Why measure OEE?
• Facilitate Continuous Improvement
• Identify efficiency losses (and opportunities
for improvement) in detail...
• Minor stops
• Slow running
• Material scheduling failures
• Quality issues
• Line and machine downtime
• ‘No Production Required’ windows
KEEPING INDUSTRY MOVING AND IMPROVING...

7. OEE: the basics
168 hour week
No
Scheduled Production Time Produc
tion
Plan
No Brea
Availability 65% Materi k
No
Staff
als Dow
Slow n
Minor
Performance 67% Runs Stops
Quality 92% Rejects
OEE 40% 60% Opportunity for Improvement
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8. Gathering the data
• Automated metering
• Meter reference
• Date & time
• Meter reading
• Manual
• Area / Line / Asset
• Date
• Meter reading
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9. Monitoring Energy
• Energy consultants have offered this type of
service for years
• They can provide
• Energy consumption by site
• Sometimes by zone/area
• Graphs over time
• Accurate analysis can be difficult due to a
shortage of meters
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10. Standard Approach: Limited Meters
Zone A - C, Week 01 - 2012
510
505
500
495 kWh
490
485
480
Zone A Zone B Zone C
Too few meters: accurate analysis is
restricted.
Zone B has used the most electricity, but
where and why?
KEEPING INDUSTRY MOVING ANDfor a longer period?
Has Zone B run IMPROVING...

11. Better: Energy Consumption by Line
Lines 01 - 05, Week 01 - 2012
700
600
500
400
300 kWh
200
100
0
Line 01 Line 02 Line 03 Line 04 Line 05
More meters: we can compare electricity usage
between production lines.
But we still can’t tell if Line 04 has run for a longer
period.
KEEPING INDUSTRY MOVING AND IMPROVING...

12. Even Better: Energy Consumption by
Asset
Line 01 - Assets, Week 01 - 2012
500
400
300
kWh
200
100
0
Filler Capper Boxmaker
More meters: the filler has consumed the
most electricity
But we still don’t know how many
products have been made.
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13. Full Picture: Energy and Product
Produced
Base kWh load Performance blip Higher than base
load, production has
finished and staff
forgot to turn off the
glue unit
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14. Energy Usage with Drill down to
Assets
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15. Energy Usage Over Time with Units
Produced
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16. Gathering the Data
Pulse Meters for Gas & Water
•OEE already provides:
•Asset Structure
•Running Hours
•Products Made
•Stoppage Events
•Productivity
•Utilisation
Current
•EnergyData feeds
Transformers
will provide:
•Energy Consumed
•Energy per Production
unit by time
•Energy usage
comparisons:
•Line / Shift / Product
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17. Opportunities
• Can we turn heaters on later?
• Can we install more efficient heaters?
• Can the plant run faster for the same energy
usage?
• Can any equipment be powered down during a
breakdown or Production stoppage?
• Can we automate power shutdown?
• Can we use OEE analysis improve in these areas:
• Minor stops
• Slow running
• Material scheduling failures
• Quality issues
• Line and machine downtime
• ‘No Production Required’ windows
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18. ROI: Bakery
Return on Investment per
Costs
production line £
High volume OEE system 4,000
Internal manpower £
High waste
allocation at start up 1,000
Low product unit price £
High energy cost Total 5,000
Significant quality monitoring
Manual data capture Potential Savings per
1%
Some opportunities for manpower Day Value now improvement
reduction £ £
Product sales value 24,000 240
Daily throughput 80000
£
Sales revenue per unit 0.30
£ £
Cost of Waste 1,500 15
£ £
Manpower 2,500 25
£ £
Energy 7,000 70
£ £
Quality management 100 10
£
Total 360
KEEPING INDUSTRY MOVING AND IMPROVING... on Investment
Return 14Days

19. ROI: Spirit Bottler
Return on Investment
Costs
per line £
High volume OEE system 15,000
Internal manpower £
Low waste
allocation 1,500
Moderate product unit price £
Steady energy usage Total 16,500
Automated quality monitoring
Automated data capture with Potential Savings
1%
manual input per Day Value now improvement
Some opportunities for £ £
manpower reduction Product sales value 28,000 280
Daily throughput 7000
£
Sales revenue per unit 4.00
£ £
Cost of Waste - -
£ £
Manpower - -
£ £
Energy - -
£ £
Quality management - -
£
Total 280
KEEPING INDUSTRY MOVING AND IMPROVING... on
Return
Investment 59 Days

20. ROI: Tractor Factory
Return on Investment Costs
for the site OEE system
£
100,000
Low volume Internal manpower £
Low waste allocation 20,000
High product unit price £
Total 120,000
Steady energy usage
Significant quality monitoring
Automated data capture with Potential Savings
0.01%
manual input per Day Value now improvement
Few opportunities for £ £
manpower reduction Product sales value 12,000,000 12,000
Daily throughput 120
£
Sales revenue per unit 100,000
£ £
Cost of Waste - -
£ £
Manpower - -
£ £
Energy - -
£ £
Quality management - -
£
Total 12,000
KEEPING INDUSTRY MOVING AND IMPROVING... on
Return
Investment 10Days

21. Summing Up
• The drive to increase energy efficiency will
continue
• Better management of energy usage will be
required
• Better management will require better
information
• Good information is provided by more & higher
quality data
• Restrict energy usage to what is required to
PRODUCE
• OEE systems with Energy Monitoring will
deliver the information required
KEEPING INDUSTRY MOVING AND IMPROVING...