Performance and Uptime Analysis for Production Lines

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Performance and Uptime Analysis for Production
Lines
Con Agra Team Mike Tracy Bob J.
Narcum Larry Roberts University of Arkansas
Team Fernando Tovia Erhan Kutanoglu,
Ph.D. Terry R. Collins, Ph.D., P.E. Earnest
W. Fant, Ph.D.,P.E.
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Outline

• Introduction
• Phase I Performance Analysis in Production Lines
  DA1 and DA2
• Phase IISanitation Procedures and Scheduling
• Phase III Implementation

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Introduction

• Determine key operating factors
• Analyze HPR reports
• Feedback from departments that influence line
  performance
• Maintenance
• Sanitation
• Microbiology
• Compliance
• Key Operating factors
• Line speed
• Rework
• Downtime
• Sanitation and maintenance performance

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Process rework
Late start of sanitation
Late start for maintenance
No time for line tune-up.
Bad start and 1st hr performance
Increase in stops and breakdowns
Effects of key operating factors
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Performance Analysis in Sanitation

• Production and sanitation interaction
• Cleaning the line during production shift
• Do not let the food dry
• Design and clean in place devices
• Supervise the performance of the floor person on
  a continuous basis
• Sanitation during lunch and break
• Develop a systematic cleaning procedure
• Define the responsibilities of the lead person
• Production role in sanitation activities
• End-of-shift cleaning while processing the rework
• Change DA2 to two motor-drive chain for reducing
  rework processing time

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Sanitation Procedures

• Phase I
• Short term implementation
• Quick and value added solution
• Phase II
• Medium-term and time consuming solutions
• Long-term implementations

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Sanitation Analysis

• Initial conditions
• Control product re-supply near the end of the
  shift
• Overlap the schedule of floor person with the
  sanitation schedule
• Implement a formal procedure with the PML team
  to empty all the pipes and food deposits directly
  to containers
• Sanitation Procedures
• Divide the line in sections and assign each
  section to a sanitor to avoid workers working
  against each other
• All sections must synchronize their work
• Develop key performance indicators for sanitation
• Timeliness
• Quality of sanitation
• Downtime and delays

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Line Sections during Sanitation
Top to bottom
Outside
Area 1
Area 3
Outside
Inside
Inside
Outside
Area 2
Area 4
Common cleaning area
More greasy area
Less greasy area
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Phase III- Implementation

• Measures of performance
• Project scheduling for assignment of sanitation
  crew based on resources and time constraints
• Implement Sanitation Control Report
• Long term implementations
• Evaluate the feasibility of changing from Clean
  Out of Place (COP) to Clean In Place (CIP)
  sanitation procedures and equipment over time

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Benefits of the Project

• Tangible Benefits
• Reduction of sanitation cycle time in 1.5
  hours/per day ( 30)
• Time reduction in processing the rework
• Elimination of sanitors idle time
• Reduction in 2245 man-hours per year
• Intangible Benefits
• The proper use of the 1.5 extra hour per day by
  maintenance and production departments could
  result in a 2 increase in the Uptime.
• Allow more time to maintenance department to
  perform preventive and predictive maintenance