1.
Lead Time System (LTS) Paul Hernandez Principal MIMITAR, LLC

2.
Tour of Existing Installation <ul><li>Presented are several key elements of the LTS in it’s native environment </li></ul>

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HMI in Action

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HMI in Action (existing PC & Touch Screen)

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Actual HMI Desktop

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Command and Control Interface

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Plasma Display

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Harsh Environmentally Proven

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AGENDA <ul><li>Historical Events </li></ul><ul><li>Definition of Lead Time </li></ul><ul><li>System and capability overview </li></ul><ul><li>Question and Answer session </li></ul>

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Historical Event <ul><li>Prior to inception, we saw some pressing problems faced by many manufacturing support teams. The struggle to maintain a consistent production flow did not allow them to increase efficiency in both their throughput and their jobs. A lot of time was spent simply putting out fires. With many concurrent production items and processes in the shop floor, it was difficult to understand, monitor and control what was happening on the shop floor. </li></ul><ul><li>It is out of this need that LTS was created. </li></ul>

11.
Definition <ul><li>Lead Time : In manufacturing, leadtime is the assumed elapsed time from the point of entry of a job into production to its completion. It is normal to consider manufacturing leadtime which consist of five separate elements : </li></ul><ul><ul><li>Set-up (time to set the machine up for the job) </li></ul></ul><ul><ul><li>Queue time (time spent in queues waiting to begin </li></ul></ul><ul><ul><li>Run (the time occupied by actual manufacture) </li></ul></ul><ul><ul><li>Wait (the time waiting after manufacture has been completed) </li></ul></ul><ul><ul><li>Move (the time spent moving the job to its next destination) </li></ul></ul><ul><li>In whatever way it may be sliced, almost always in the traditional job shop environment, 90% of leadtime is found to comprise of queue time. </li></ul>

12.
Lead Time System <ul><li>Capability: </li></ul><ul><li>Lead Time </li></ul><ul><li>Service Level </li></ul><ul><li>Product Mix Avoidance </li></ul><ul><li>Real Time Tracking: Router and People </li></ul><ul><li>Printing </li></ul><ul><li>Reject Tracking </li></ul><ul><li>Log Entry </li></ul><ul><li>Department Communication </li></ul><ul><li>Administration </li></ul><ul><li>Currently Validation Ready CFR 11 21 </li></ul>

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Plasma Display <ul><li>Plasma Display </li></ul><ul><li>Plasma Display form includes following items: </li></ul><ul><ul><li>W/O table showing New and In-Progress cases in FIFO order mode for current day </li></ul></ul><ul><ul><li>Total New Cases per day </li></ul></ul><ul><ul><li>Summary table showing current day statistics table by shift </li></ul></ul><ul><li>Plasma Display form will automatically show (in cycle) all locations with W/O and statistics data gathered during the day. </li></ul>

14.
Lead Time Report

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Lead Time Report Detail

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Service Level <ul><li>Service Level I Report (rework excluded) </li></ul><ul><li>Lead Time Menu: Reports Advance -> Service Report </li></ul><ul><li>Lists service level per customer without rework data. Daily calculation enables ‘To’ date control filter, then report is generated for all Work Orders done during this date range. If Daily calculation is not checked report shows data for (Today’s date – 14 days) date. </li></ul><ul><li>Service Level I report use following date range logic: when querying data ‘Time span’ value is being subtracted from From/To dates. On web page user sees dates before subtracting is done. </li></ul>

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Service Level Report

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Router Tracking <ul><li>Router Tracking Report </li></ul><ul><li>Lead Time System Menu: Report Advance -> Router Tracking </li></ul><ul><li>Report shows all Work Orders (Routers) which are processed longer than Processing Days or are still not finished. Report shows data between ‘To’ Date – ‘Lookback days’ = ‘From Date’ and ‘To Date’. </li></ul>

19.
Router Tracking Report

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Router Tracking Detail Report

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People Tracking <ul><li>Lead Time System Menu: Report Advance -> People Tracking </li></ul><ul><li>Report shows operators (people) Work Orders done daily with Average, daily with Total Count and daily Efficiency with average (3 separate cross tables). On the last page report shows histogram chart showing all operators and their Average Work Order value. </li></ul><ul><li>If there is no location or shift selected user has to enter Target Value on the web form. Normally target value is taken from Location Target Value defined per shift on Location Target Values Administration form (Admin -> Target Values) </li></ul><ul><li>Below there are 4 screenshots of this report: </li></ul><ul><ul><li>Daily Work Order with Average </li></ul></ul><ul><ul><li>Daily Work Order with Summary Count </li></ul></ul><ul><ul><li>Daily Work Order efficiency % </li></ul></ul><ul><ul><li>Average Work Order per Operator chart </li></ul></ul>

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People Tracking Report

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People Tracking

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Work Order <ul><li>Work Orders </li></ul><ul><li>Administrator can view work orders with data filtered by: </li></ul><ul><ul><ul><li>date range, </li></ul></ul></ul><ul><ul><li>lot ID, </li></ul></ul><ul><ul><li>location, </li></ul></ul><ul><ul><li>operator, </li></ul></ul><ul><ul><li>Status. </li></ul></ul><ul><li>By left clicking on Lot ID user can view specific Work Order in details </li></ul>

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Work Order Report

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Work Order Report Details <ul><li>After that a pop up window, with details relative to particular W/O, will occur. User can modify Part Count and Status for a work order if there was some invalid value entered into the system. Person changing WO data can enter reason value if appropriate. User can view WO change log by clicking Show WO ChangeLog link. </li></ul>

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Work Order Report Detail

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Statistical Report <ul><li>Statistics form includes: </li></ul><ul><li>Work Order table showing (Lot ID, W/O# : RLS #, Quantity, Part # and Part Description) </li></ul><ul><li>Summary table showing statistics by shift </li></ul><ul><li>Total New Cases per day value </li></ul><ul><li>Possibility of filtering information by: </li></ul><ul><ul><li>date range, </li></ul></ul><ul><ul><li>status: All, New, In progress, Completed, </li></ul></ul><ul><ul><li>customer, </li></ul></ul><ul><ul><li>lot ID, </li></ul></ul><ul><ul><li>location, </li></ul></ul><ul><ul><li>part type, </li></ul></ul><ul><ul><li>location, </li></ul></ul><ul><ul><li>shift, </li></ul></ul><ul><ul><li>operator </li></ul></ul><ul><li>Possibility of generating two separate reports: one for W/O table and other for Summary table </li></ul>

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Statistical Report

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Rework Report <ul><li>Administrator can view Reworks reports with data filtered by: </li></ul><ul><ul><li>date range, </li></ul></ul><ul><ul><li>lot ID, </li></ul></ul><ul><ul><li>customer, </li></ul></ul><ul><ul><li>part type, </li></ul></ul><ul><ul><li>location, </li></ul></ul><ul><ul><li>operator, </li></ul></ul><ul><li>Reworks Report provides Administrator with information, how many Work Orders due to technical reasons were reseted. Reworks Report also displays duration time and number of resets in each Work Order </li></ul>

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Rework

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Casting Log Report <ul><li>Casting Log Report </li></ul><ul><li>Operator can view work orders with casting log data filtered by: </li></ul><ul><ul><li>date range, </li></ul></ul><ul><ul><li>customer, </li></ul></ul><ul><ul><li>part type, </li></ul></ul><ul><ul><li>lot ID, </li></ul></ul><ul><ul><li>operator </li></ul></ul>

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Casting Log

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PMA

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Lead Time System Options <ul><li>Other Optional Features: </li></ul><ul><li>Real-time Machine Interface Control </li></ul><ul><li>Inventory Control </li></ul><ul><li>Maintenance Response System </li></ul><ul><li>Overall Cell Efficiency (TPM) </li></ul><ul><li>Connection to most Financial Packages: Quicken to Oracle Financial </li></ul>