Clarity and transparency are the keys to success
The Seiki solution combines both automatic data collection via signals from the machine tool and a simple user interface that enables the operator to manually select downtime reason codes recording the categorisation of the losses. The automated data capture provides measurement accuracy and speed benefits, whilst the operator input enriches the data with a fuller picture of your resource availability for the real insight.
Getting staff buy-in is one of the most important ways to achieve the full benefits of any improvement programme. In our experience, the introduction of any form of monitoring solution needs to be done with the end-user involved as early as possible. This helps to create a positive perception of the planned change to their work routine, demonstrates from the start that you value their input and starts to instil a sense of personal ownership of the information from the beginning. It’s all about empowering and inspiring your team to embrace the change and actively participate in making the necessary improvements.
Continuous Improvement
Machine Monitoring is a critical element in improving your productivity but it doesn’t stop there. Once you have visibility of the significant loss causing events that are having the biggest impact on your throughput capability (potentially a quick win), you can start to address the smaller, often more chronic Performance losses that can take longer to uncover and resolve. This is where the modularity of the Seiki solution helps. You can start building your solution with any of our modules and use the insight that they provide to determine your best next steps for improvement and/or investment.
Our Recommended Approach
| Step One |
For clarity, consider what KPIs you will use, how frequently they will be reviewed and what business management reports that they will feed into. This will help ensure that the process is supported at senior management level. You can then define what data you will collect and a set of reason codes. To help get you started Seiki Monitoring comes with a standard out of the box matrix. You should then consider what additional non-value adding events and process constraints you wish to monitor and tackle. |
| Step Two |
For transparency, share your definitions with management, supervisors and operators and agree their roles in capturing and reporting the data. Part of this should be agreeing how the information will be used for improvement actions, both at a tactical and strategic level.
Related content: Standard Seiki Machine Monitoring Matrix (available from your account manager) |
| Step Three |
Now that you have a standardised process and have started to capture your data, maintaining it is key. We recommend scheduling a regular data audit, particularly in the initial stages of the implementation or following the introduction of any new variables. This will ensure that the logic and definitions have been effective and will help to build confidence in the information being captured, which is important when making strategic decisions. The main benefit of a solution that enables you to define your own loss causes, is that you can more closely align it with your environment. It may be that you need to adjust your reason codes or adapt a process to derive meaningful data as you start to develop a clearer picture of your resource activity. |
| Step Four |
Machine utilisation analysis will provide the insights you need for continuous improvements. It should be used daily by supervisors to identify and assign tactical improvement actions. We find that discussing and sharing this information with Operators, for example at daily stand up meetings, helps to make those smaller margins of improvement. Both from a deeper level of engagement and by creating a degree of friendly competition. The data should be reviewed regularly at a management level to set and track performance targets and identify strategic improvement initiatives. |
| Step Five |
Make use of remote access to a live status view on either a tablet or mobile and large format screens located strategically through the building to increase visibility and awareness within the wider team. This will help to keep the whole business focused on keeping your spindles turning. |
| Step Six |
Feed your utilisation data into your finite capacity planning and scheduling system as a resource efficiency factor. This will greatly improve the accuracy of your schedules and therefore help with improved on-time delivery performance.
> Related product: Seiki Scheduler |
