Streamline your production time at a stand-alone workstation!
As a business manager, you are able to calculate your KPI to track and measure progress using Lean along with the Toyota model.
But how do you control and optimize a stand-alone workstation for bench assembly, where a single operator performs preparation, assembly, and packing?
It can be done with our standalone solution OEE for station assembly!
OEE is a form of KPI and stands for availability, plant utilization, and quality.
OEE for station assembly facilitates continuous improvement work. It can show that set-up times can be reduced if the handling of incoming materials is simplified or if the packing is done more smoothly.
The operator receives guidance and continuous information from OEE for station assembly. An LED display (BiDisp3) and/or computer screen shows and compares the optimal time consumption with how the work progresses in real time during preparation, assembly, and packing.
Benefits of having a standalone solution OEE for station assembly
- Guides staff for optimization
- Provides knowledge that enables continuous improvements: where is the bottleneck at the workstation, and how does it change considering, for example, time of day, day of the week, operator, picking technology, packaging technology, number of breaks, and their length?
- Logs results that can be exported to Excel
- Easy to get started
- Lowers costs
- Low price due to few components, as OEE for station assembly, is intended for a single workstation and not an entire production line.
- Orders can be queued for several days ahead. The queue order can be adjusted
- The orders can be adapted to the operator and type of product.
OEE (Overall Equipment Effectiveness) is a key figure that stands for availability, plant utilization, and quality. 100% OEE implies a continuous maximum production rate without any breaks and with maximum quality, which is not realistic. But most manufacturing companies are unnecessarily low, around 60%. In other words, there is clear potential for improvement here.
Via an associated web application, the operator creates one or more work orders with information on how many articles are to be assembled or manufactured and how long preparation, assembly, and packing are expected to take. The web application is also used to start the current order. The operator then uses a mechanical push button or clicks through the web application to mark when each workstep is completed. A non-contact sensor can be an option. When the order is processed, the operator indicates how many of the products are not of perfect quality.
Each order with results and statistics is logged in the web application and can be read afterward, as can the OEE value. A team leader with access to the gateway can log into the web application from another location to read logs or place orders.
Measure your productivity
You can only streamline your production if you know how it operates and performs. Measure your productivity using OEE, Overall Equipment Effectiveness, to find out how much of your planned production time is actually productive. If you can improve your bottleneck, you can improve your whole process.
Measure your availability by monitoring the part of your planned production time your production equipment is actually running. Identify and try to eliminate your availability losses in the form of unplanned stops, like equipment failures and material shortages, and reduce planned stops, like set-up time.
Measure your performance by monitoring the part of your planned production that is backlogged because you don’t keep the fastest possible Takt. Identify and try to eliminate or reduce your performance losses in the form of small continuous stops that the worker solves without help from maintenance and therefore are easy to become blind to, and everything else that makes you lose speed.
Measure your quality by monitoring the part of your produced parts that are OK after having gone through your production process. Identify and try to eliminate or reduce your quality losses in the form of waste or rework.
What makes for a great OEE value?
100% OEE means you’re producing as quickly as possible, without any downtime, and everything you produce is OK. In reality, the majority of manufacturing companies have around 60% OEE, which means there are clear losses and many opportunities for improvement. Let’s get started!
A simple stand-alone solution with few components
OEE for station assembly requires only the following:
- A local gateway for the control system
- A cloud-based account for setting up and managing orders
- An IO unit and cable between the gateway and LED display BiDisp3.
- Any signal light that indicates when staff need help via an andon function
- Equipment for registration, options:
- Non-contact sensor
- Mechanical push button