Moving From Art To Science
- 1. Moving From Art to Science Manufacturing in the 21st Century
- 2. Your Workforce Past Present Employee Life Less than 3 years Progression Decade Months Living for Future Now Work life balance Work Life Process Art Control/data Process knowledge High Low Work Load Reasonable Overburdened Job Function Well Defined Multiple Roles Computer knowledge Low High Moving From Art to Science
- 3. Cost + Control Resource Cost Control Materials $$$ Yes People $$$ ? Assets $$$$$$$ Yes Parts $$ Yes Process ? ? Improving Cost Control & Throughput with Process Control Your process combines the costs of materials, people, assets, and parts for all activities needed to make each product. When you control each area, you can control your costs.
- 4. Increase Throughput • Raw material receiving / storage • Processing/batching • Pasteurized/processed product storage • Filling / Packaging • Effluent • CIP Do you have the visibility of these areas of the process? If you could improve flow through one area would it improve performance and profitability? Improving Cost Control & Throughput with Process Control
- 5. Process Control • What should you control? – Variables • Why do you need to control them? – Repeatability – Consistency • How are you going to control them? Improving Cost Control & Throughput with Process Control
- 7. Receiving ► Problem: Only visibility to receiving operations is paper trail • Original hardware & software controls to move milk, actuating pumps, valves, air-blows ► Solution: Added additional hardware & software • Meters and software to integrate compositional data, truck, transport data, testing data, billed and scaled amounts, destination tanks, flows and tank levels ► Results: Caught losses of milk left on tanker (20 gal to 1000 gallons) • Immediate HMI view and notification on large losses • Used information to study trends by operator, driver, carrier, day of the week, receiving bay, etc. • Discovered loss occurring late on weekends with one driver • Broke multi-million dollar theft ring Real Life Dairy Manufacturing Problems and Solutions
- 8. Cream Press ►Problem: “Blew Cream Press” • Lost material, lost time, inconsistent fat level ►Solution: New plate package and Automated controls ►Results: Consistent BF, improved temperature control, improved yield • Improved visibility of the process Real Life Dairy Manufacturing Problems and Solutions
- 9. Managing Inventories • Collection tools: Paper and pencil or sensor technology • Automation: Track amount, usage and temperatures • View in plant at HMI and on desktop • Provide alerts and information for plant operations, purchasing, sales, planning, and other departments • Provide emailed or live inventory to suppliers to assist in managing inventory levels to match usage Real Life Dairy Manufacturing Problems and Solutions
- 10. Contaminated Product • Discovery: Visually on display (Tank temperature too high, volume too high) • Correlation: Events – Receiving and CIP • Identification: Sequence of events and operators responsible • Control: Liability ChemicalsMilk Real Life Dairy Manufacturing Problems and Solutions
- 11. Batch Typical Problems Variables to Measure & Control Missing Ingredients • Flows • Quantities • Ingredients • Agitation • Mixing • Temperature Wrong Ingredients Wrong BF Under-Stabilized Over-Stabilized Over-Fortification Wrong pH Wrong BRIX Air Incorporation Real Life Dairy Manufacturing Problems and Solutions
- 12. Pasteurizing Process – Under Utilized Idle Real Life Dairy Manufacturing Problems and Solutions Forward Flow CIP
- 13. Pasteurizing Process – Time Lost Recycle Divert Forward Flow Real Life Dairy Manufacturing Problems and Solutions CIP
- 14. Filling / Packaging Quality, Yield, Utilization Issues Measurements Area Affected Leakage Visual/Electronic Shrinkage Over/under fill Scale/Volumetric Shrinkage/Lost Sale Volume Metered in vs. Package Count Meter value, Sensor Yield and Shrinkage Lack of packaging Bottles, packages per minute OEE CIP/COP Duration of CIP Availability Downtime too high Number/duration per shift per reason OEE, Distribution Changeovers Number/duration per shift Throughput Wrong product Product, tank, label, time Shrinkage, OEE Real Life Dairy Manufacturing Problems and Solutions
- 15. Cost Control and Process Control ►“Get what you pay for” ►Control inventory • Monitor Receipts vs. Billing vs. Shipments ►Effective use of resources and assets • Waste or Loss Reduction • Resource in equals Finished Product out ►Efficiently use of resources and assets • Manpower reductions • Increase machine time available for sales ►Develop accurate costing • Activity Based Costing
- 16. Sustain Results ►Train and Empower People • Job knowledge to make good decisions • Authority to make decisions ►Provide Effective Tools and Systems ►Provide Accurate, Actionable Information • Information is real-time, with correlated events ►Act on the Information • Given the responsibility and training to act • Held accountable for actions ►Achieve Sustained Results • Ownership and Reward
- 17. Shrink Control/Loss Prevention ABC Dairy ► Problem: • Monthly loss of butterfat (3%), total loss (2.5%) • Needed visibility because only knew loss on monthly basis ► Solution: • Hardware/software installed to measure product metered into and out of each area of the plant. • Developed daily utilization reports based on predicted or expected yield vs. actual and identify loss by area. • Reduced loss in receiving, storage, batching, processing, and packaging to less than 1%. ► Results: • Annual savings: $600,000 Controlling Costs and Sustaining Results
- 18. Effluent/Waste Water XYZ Dairy ►Problem: Fines for Fats, oils and grease in waste stream ►Discovery: • Test for fats, oils, greases • Butterfat was the largest contributor ►Solution: • Hardware/software; installed optical sensor, opacity meter, recording system, annunciator • When sensor alarmed, immediately responded to all plant areas • Isolated areas and found sources (CIP, Separator, Cream Loadout) • Developed new procedures and added programming to reduce loss of product and eliminate violations ►Results: • Annual savings: $80,000 Controlling Costs and Sustaining Results
- 19. Rudy’s Top 5 Focus Areas