Improving Efficiency Real time Performance Management

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Improving Efficiency Real time Performance
Management
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Finbar Gallagher Bio

• Founder of Fraysen Systems,
• 20 years experience developing systems which
  deliver information critical to successful Lean
  Manufacturing.
• Hewlett Packard Medical Devices
• Hewlett Packard Inkjet Supplies
• Tellabs Inc.
• Bachelors of Science in Electronic Engineering
  from Dublin University
• Master of Science in Systems Engineering from
  Boston University.

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Agenda

• Crisis
• Roadblock
• Solution
• Requirements
• Results

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The Burning Platform

• Hourly Costs
• US . . . . . . . . 21.83
• Ireland . . . . . 18.80
• China . . . . . . . 0.92

China is revolutionizing the relative prices of
labour, capital, goods and assets in a way that
has never happened so quickly before The
Economist, July 28, 2005
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Crisis
Lean with traditional IT (ERP, MES, SCADA)
manual methods
Dont have information to understand issues in
time to make a difference
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Information is Roadblock

• Too Late
• Black Holes
• Disassociated
• Cant get the Big Picture

!
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Improvement is Stalled

• Many Black Holes ? hiding problems root
  causes
• Data too late, highly subjective
• Cannot separate key metrics, e.g. Uptime and
  Performance ? no root cause or responsibility
• Data analysis huge paper trail ? information
  overload, difficult to prioritize projects.

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But

• Problems can be solved
• Not rocket science
• Resolution typically application of common sense
• Perennial challenge is lack of information which
  is
• Complete
• Specific
• Trusted, and
• Timely

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Solution
Weeks
Days
Shifts
Hours
Minutes
Seconds
Machines
Material
People
Product
Process
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Real-Time Performance Management Systems

• RPM Systems enable Manufacturers to understand
  and control the interaction between people,
  equipment, and product, and so manage the
  operation to its maximum capacity
• Real-time That which is relevant to the
  real-world operations of a company in time,
  on time, or right time
• Managing Automation, 2004

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Business Process Change
Real time information causes you to reassess
your course of action Gartner Group, 2005

• With RPM, manufacturers can
• Sense the environment more intelligently
• Predict and Prevent problems before they occur
• Identify and correct problems as they occur

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To Succeed, You Must Have
With Full History
In Real-time
Integrated View of Whole Process
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Challenges

• Access to all equipment / information
• Equipment state mapping
• Process mapping
• Uncovering true management process
• Agreeing common metrics
• Cultural change

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Requirements Map
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Requirements Map
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Results
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Results
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Summary

• The tools now exist for discrete manufacturers
  to
• Get timely, integrated information,
• Solve problems, and
• Achieve World Class competitiveness
• Real-time Performance Management