A Magical ride on a production floor.

1. Manufacturing Intelligence

2. The Production Floor
 Departments
 Workers
 Work Cells
 Operations
 Machines
 Manual Work

3. The Planned Production Process

4. The Planned Routing in Priority

5. Production Reporting Screen

6. Discovering the Actual Production Process
With
Disco
Example Deliverables

7. Some Possible Deliverables
 A process map of the executed production processes
 Conformance Checking
► Deviations
 Performance Analysis
► Machines
► Operators
► Idle times
► Bottlenecks
 Focused analysis of:
► Breakdowns
► Rework
► Rejected
► Parts
 Comparison of workers performance
 Analyzing transfer of parts from the production floor to a subcontractor*.
* Published in a separate presentation

8. The data Source
 The production reports data are exported from the ERP (or MES)
The mandatory data

9. The Data in Disco
 The Production data are configured and imported to Disco for process discovery

10. The Process in Reality
 The actual process is animated based on the production data
 To view the animation press here.
Work orders starting the
process
A Bottle Neck
Operation Date
Indication of
work loads

11. The Actual Process Model
 A visual map displays the flow of the process based on the sequence of operations
 Boxes represent the operations
 Arcs display the sequence of the operations performed on work orders
 Numbers at the arcs and in the boxes represent frequencies of operations and paths
 The thickness of the arcs and the coloring of the boxes visually support these numbers.

12. Analysis of Operations

13. Revealing Deviations from Routing
 For some work orders, the process starts with different operations then defined in the
routing (circled in red)

14. Locating the Slow Work Orders
 The Performance filter is used to retrieve the desired work orders by duration

15. The Model of the Slow Work Orders
 Numbers in the boxes represent the mean duration of the operations
 Numbers at the arcs represent the mean idle time between operations.
 The thickness of the arcs and the coloring of the operations visually support these numbers.

16. Statistics About Products in the Slow Work Orders

17. Demonstrating the Bottlenecks with Animation

18. Analysis of Work Cells

19. The Process Model by Work Cells
 Boxes represent the work cells and the operations done in them
 Arcs display the paths of the work orders among the work cells
 Numbers in the boxes represent work orders in work cells
 Numbers at the arcs represent work orders transferred between work cells
 The thickness of the arcs and the coloring of the boxes visually support these numbers.

20. Locating the Longest Idle Times
 The Performance filter is used to retrieve the work cells with the longest idle times between
operations

21. Longest Idle Times in Work Cells
 The numbers at the arcs represent the longest durations of idle time between operations
in the work cells
 The yellow arrow represents a repeating operation in the same work cell.

22. Statistics About Work cells
 A statistics display about the work cells with the long idle time

23. Statistics About Operations
 A statistics display about the operations in the work cells with the long idle time

24. Analysis of Breakdowns

25. Statistics About Work cells with Reported Breakdowns

26. Statistics About Breakdown Reasons

27. Analysis by a Selected Breakdown Reason

28. The Impact of a Breakdown on a Selected Part
 The operation with the ellipse was reported as a breakdown
 The red arrow points at a delay in the process (compared to one indicated by the green
arrow)
With BreakdownWithout Breakdown

29. Analysis of Rejected & Rework

30. Statistics About Rejected Parts

31. Statistics About Rejected Quantities

32. Statistics About the Operations Involved

33. Statistics About the Workers Involved

34. Comparing Operations & Workers
With rejected parts
Without Rejected parts

35. A Comparison of Processes
With Rejected partsWithout Rejected parts

36. Retrieving Work Orders with Rework

37. A Comparison of Processes
With ReworkWithout Rework

38. Additional Analysis

39. Comparing Production Processes of 3 Parts

40. Comparing Different Machines for a Selected Part
Machine 4Machine 5

41. Comparing Fast and Slow Work orders of a Selected Part
Fast Work OrdersSlow Work Orders

42. For further info & demo please contact:
Dafna Levy
Email: dafnal@nool.co.il
Phone: +972 (0)54-6881739
Intelligent Process Management