TEEPTRAK – Connect to your industrial potential

Category: Industrial maintenance

Industrial maintenance is key to ensuring production continuity and preventing costly downtimes. Explore the latest trends in preventive, predictive, and corrective maintenance, along with best practices to enhance equipment reliability and boost industrial performance.

  • Understanding Machine Supervision to Optimize Your Industrial Processes

    Understanding Machine Supervision to Optimize Your Industrial Processes

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    In modern industry, machine supervision plays a key role in optimizing performance and managing production infrastructures. Thanks to advances in computing and monitoring solutions, companies can improve equipment availability, prevent breakdowns, and maximize efficiency. This article explores the tools and software used in supervision, their role in the industry, and the benefits they bring to companies in terms of control, safety, and data management.

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    What is Machine Supervision?

    Definition and Objectives

    Machine supervision refers to the set of processes and applications used to monitor, control, and optimize industrial equipment. It relies on a system capable of collecting real-time data, analyzing machine status, and sending alerts in the event of a problem. The primary goal is to ensure optimal performance by guaranteeing equipment availability and safety while reducing the risk of production downtime.

    Importance in the Industry

    In an industrial environment, supervision is essential for optimizing resource usage and improving equipment management. In France and beyond, companies rely on monitoring solutions to detect anomalies and boost productivity. Implementing supervision software not only increases performance but also enhances the management of servers, networks, and production infrastructure.

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    Supervision Tools and Software

    Introduction to SCADA Software

    SCADA (Supervisory Control and Data Acquisition) systems are essential tools in industrial supervision. They collect and analyze machine data to optimize production process management. These software packages provide an interface for real-time control, enhancing equipment safety and availability.

    Key Features of Supervision Tools

    Supervision software includes several key features, such as real-time monitoring, alert management, and performance analysis. Some tools offer light-based alert systems, advanced user interfaces, and plugins for better customization. Compatibility with networks and servers ensures optimal data availability, thereby supporting better management of industrial resources.

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    Optimizing Industrial Performance through Supervision

    Cost Reduction and Efficiency Improvement

    Using a supervision tool allows companies to optimize resource usage and reduce costs related to maintenance and production interruptions. By monitoring real-time data, companies can identify inefficiencies and enhance overall performance. A well-implemented solution also allows early detection of machine failures, helping to avoid costly repairs and unexpected downtime.

    Failure Prevention and Continuous Monitoring

    With a monitoring system in place, industries can detect anomalies before they become critical. Supervision tools enable data analysis and precise control over machine operation. The installation of dedicated servers and software facilitates remote access to information, ensuring continuous supervision and better incident management.

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    Frequently Asked Questions about Machine Supervision

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    A supervision tool is a software or system used to monitor and control industrial infrastructures. It collects real-time data, analyzes performance, and generates alerts in case of anomalies. These solutions are used to ensure safety, availability, and optimal resource utilization.

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    Supervision refers to all the techniques and tools used to monitor, analyze, and control a system or network of machines. It plays a crucial role in industry by ensuring efficient management of data and production processes through specialized software.

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    There are several types of supervision, including industrial supervision, which focuses on monitoring machines and infrastructures, and IT supervision, which covers networks, servers, and digital systems. Some companies also use specific solutions like Nagios for monitoring data and applications.

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    The supervision function consists of monitoring, controlling, and optimizing a system to ensure its availability, safety, and performance. It enables the detection of problems, anticipation of failures, and smooth management of resources and information.

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  • OEE monitoring software : optimize your equipment efficiency

    OEE monitoring software : optimize your equipment efficiency

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    In the competitive world of manufacturing, ensuring optimal equipment efficiency is essential for maintaining high productivity. OEE (Overall Equipment Effectiveness) monitoring software offers a powerful solution for companies to improve machine performance, reduce downtime, and enhance overall production effectiveness. By providing real-time insights and actionable data, this software enables manufacturers to make informed decisions that drive continuous improvement across the production line.

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    What is OEE monitoring software?

    OEE monitoring software is a specialized tool that helps manufacturing plants track, measure, and optimize the performance of their equipment. It provides real-time data on key metrics like availability, quality, and speed, offering valuable information to reduce losses and increase productivity.

    Definition of OEE software

    OEE software measures how well a machine or a production line operates by calculating its OEE score, which is based on three factors: availability, performance, and quality. This score reflects the overall effectiveness of the equipment in producing high-quality products without delays or issues.

    Key features of OEE software

    Key features of OEE monitoring software include real-time monitoring, downtime tracking, maintenance scheduling, and performance analysis. It also offers customized reports that provide visibility into losses and inefficiencies within the process. Advanced tools allow manufacturers to set standards for continuous improvement and reduce production cycle times.

    Importance of OEE monitoring in production

    OEE monitoring is crucial in the production environment as it helps companies address the root issues affecting equipment performance. By analyzing the data, companies can optimize the processes, minimize downtime, and ensure high-quality product output. This contributes to greater overall productivity and plant efficiency.

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    Key benefits of OEE software

    OEE monitoring software brings significant advantages to manufacturers, from increasing data accuracy to enabling comprehensive loss analysis. These features drive better decision-making and improve operational efficiency.

    Improved data accuracy

    OEE software delivers highly accurate real-time data, helping companies track equipment performance, speed, and availability with precision. This information minimizes manual errors and allows businesses to make data-driven decisions that positively impact the production process.

    Loss analysis

    By identifying areas of loss, OEE software enables companies to focus on the root causes of inefficiencies. This could include unplanned downtime, performance drops, or quality issues, all of which can be targeted for improvement to enhance overall effectiveness.

    Historical perspective and benchmarking

    OEE software stores historical data, allowing companies to benchmark past performance against current standards. This long-term perspective helps identify trends and provides context for continuous improvement efforts across manufacturing plants.

    Production capacity analysis

    Understanding production capacity is critical for optimizing manufacturing operations. OEE software helps businesses assess their full capacity and pinpoint underutilized equipment, thereby improving overall productivity and reducing costly downtime.

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    How OEE software helps improve your manufacturing operations ?

    OEE software plays a pivotal role in enhancing manufacturing operations by providing actionable insights through real-time tracking and comprehensive analytics. These tools help optimize machine performance and overall plant efficiency.

    Real-time tracking and analysis

    Real-time monitoring gives businesses instant access to critical performance data, such as downtime, speed, and quality. This immediate visibility allows companies to quickly address any performance issues and maintain smooth operations across the production line.

    Continuous improvement analytics dashboard

    OEE software includes an analytics dashboard that continuously tracks KPIs, offering insights into ongoing process improvements. This dashboard highlights areas of loss, enabling manufacturers to take corrective actions in real time and boost production effectiveness.

    Departmental KPI displays

    Displaying KPIs for individual departments improves transparency and accountability. OEE software visualizes metrics across departments, enabling better coordination and ensuring each section of the plant is aligned with performance goals to maximize overall productivity.

    Downtime tracking and quality control

    The software excels in downtime tracking, allowing manufacturers to reduce unplanned stoppages and improve maintenance scheduling. It also enhances quality control by identifying potential losses in the production process before they become major issues.

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    How to measure OEE ?

    Measuring OEE is essential for understanding the effectiveness of your equipment and production processes. OEE breaks down into three key metrics: availability, performance, and quality. By monitoring these factors, manufacturers can accurately assess equipment efficiency and make improvements.

    OEE calculation methodology

    The OEE score is calculated using the formula: OEE = Availability × Performance × Quality. Each factor is represented as a percentage. Availability measures the downtime, performance evaluates operational speed, and quality measures defect-free products. The combined data gives the overall OEE score, offering real insight into equipment losses and opportunities for improvement.

    Practical examples and calculations

    For instance, if a machine operates for 8 hours but experiences 1 hour of unplanned downtime, its availability is 87.5%. If it runs at 90% speed, its performance is 90%. Lastly, if 95% of the products meet quality standards, the final OEE score would be approximately 74.6%. This highlights areas to analyze for improved efficiency.

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    Tips for using OEE software successfully

    Implementing OEE software can greatly improve manufacturing operations, but success depends on using the tool effectively. Follow these tips to maximize the value of your OEE monitoring solution.

    Choose simplicity

    Select OEE software that is easy to use and understand. Complex tools can overwhelm users and reduce adoption. Focus on a solution that provides clear data and intuitive reporting, allowing teams to make quick decisions without excessive setup.

    Create an OEE rule book

    Establish a standard rule book to ensure consistent OEE measurement across your plant. This ensures that every line follows the same criteria for calculating availability, performance, and quality, reducing discrepancies and improving the accuracy of reports.

    Establish accurate ideal cycle times

    Set realistic cycle times for each piece of equipment. Accurate cycle times are critical to determining true performance levels and losses. Without a well-defined standard, it becomes difficult to evaluate process efficiency effectively.

    Set achievable OEE goals

    Setting realistic and achievable OEE goals motivates teams to strive for continuous improvement. Rather than aiming for perfect OEE, aim for incremental gains that reflect true improvements in productivity and equipment effectiveness.

    Start with your shift meetings

    Integrate OEE data into daily shift meetings to keep teams informed about the performance of their machines. By discussing OEE results regularly, your team stays aligned and focused on addressing the key issues impacting production efficiency.

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    Features and options of OEE software

    OEE software comes with a variety of features and customization options to help manufacturers optimize their production processes. These features ensure seamless connectivity, real-time visibility, and flexibility for specific manufacturing needs.

    Equipment connectivity (OPC & MQTT)

    OEE software can integrate with equipment using protocols like OPC and MQTT. This connectivity allows for real-time data exchange, improving the availability and accuracy of machine performance monitoring. Tools like Evocon offer such integrations, providing better visibility across the plant.

    Customization options

    Customization options are key to adapting OEE software to your specific needs. From creating personalized dashboards to setting up specialized reports, OEE software can be tailored to analyze different aspects of the process, ensuring the right information is always accessible.

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    Benefits of implementing OEE software

    Integrating OEE monitoring software into your operations brings numerous benefits, from enhancing productivity to reducing operating costs, while supporting lean manufacturing initiatives.

    Return on investment

    OEE software provides a strong ROI by improving equipment performance and reducing downtime. The better visibility into your processes helps prevent unexpected stoppages, increasing overall plant productivity and driving significant cost savings over time.

    Lowering operating costs

    By identifying losses and optimizing maintenance schedules, OEE software helps lower operating costs. The insights gained allow you to reduce wasted resources, improve product quality, and maximize production output without overextending resources.

    Embracing lean manufacturing

    OEE software supports lean manufacturing by helping eliminate waste and improve process effectiveness. With real-time data on equipment performance, manufacturers can adopt lean practices that minimize inefficiencies and reduce unnecessary downtime, driving higher efficiency.

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    FAQ about OEE software

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    OEE software is a tool that tracks, measures, and analyzes the performance, availability, and quality of manufacturing equipment. It helps companies monitor machine efficiency and identify areas for improvement, ensuring more effective production processes.

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    An OEE score of 85% indicates that the machine is operating at 85% of its full potential when considering availability, performance, and quality. This is considered world-class OEE in most industries and shows that the process is running smoothly with minimal losses.

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    OEE is measured by multiplying availability, performance, and quality. These metrics are calculated based on machine uptime, speed compared to the ideal cycle time, and the proportion of defect-free products. The final score reflects overall equipment effectiveness.

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    Yes, OEE is a key performance indicator (KPI) used in manufacturing to measure the effectiveness of production equipment. It helps businesses track how well their machines are operating and where there are opportunities to improve productivity and reduce losses.

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  • How is the OEE calculated? (Overall Equipment Effectiveness)

    How is the OEE calculated? (Overall Equipment Effectiveness)

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    What is OEE?

    Definition and importance of OEE

    The Overall Equipment Effectiveness (OEE) is a key performance indicator used to measure the efficiency of industrial equipment. It is calculated as a percentage and takes into account three main factors: availability, performance, and quality. These elements are crucial for understanding how a machine or production line operates relative to its theoretical maximum potential.

    Availability evaluates the time during which the equipment is operational compared to the total time planned for production. Performance measures the actual production speed compared to the theoretical maximum speed. Finally, quality examines the number of conforming parts produced compared to the total number of parts made. A high OEE indicates efficient and optimal use of resources, which can lead to cost reduction, better product quality, and increased production capacity.

    Differences between OEE and TEEP

    While OEE focuses on the performance of a specific piece of equipment, the Total Effective Equipment Performance (TEEP) takes into account the entire production chain. OEE integrates additional variables such as losses related to logistics or other processes upstream and downstream of production. Thus, OEE is a more targeted tool for diagnosing and improving the performance of individual machines, while TEEP provides a broader overview of overall production efficiency.

    How is the OEE calculated?

    Total time

    Total time is the complete period during which a piece of equipment is supposed to be operational, including all planned and unplanned downtimes. It serves as the basis for measuring the machine’s availability.

    Opening time

    Opening time refers to the planned time during which production is expected to take place. It excludes planned downtime for maintenance or other scheduled interruptions.

    Required time

    Required time is the time needed to produce a certain amount of products, assuming the equipment is running at its maximum speed.

    Operating time

    Operating time is the duration during which the equipment is actually running and producing parts. It is crucial for determining availability.

    Net time

    Net time is the operating time minus performance losses due to slowdowns or small interruptions.

    Useful time

    Useful time is the net time adjusted for quality losses, i.e., the time spent producing conforming parts.

    OEE calculation formulas

    OEE is calculated by combining three main ratios that reflect the equipment’s performance.

    State time ratio

    The state time ratio is calculated by dividing the operating time by the opening time, expressed as a percentage. It indicates the equipment’s availability.

    Produced quantities

    The performance ratio is determined by comparing the actual quantity produced with the theoretical possible quantity, taking into account the maximum speed.

    Availability

    Availability is calculated by dividing operating time by total time. It shows how operational the equipment is when it is supposed to be.

    Performance

    Performance is the ratio between the actual production speed and the theoretical maximum speed. It reflects the efficiency of the machine.

    Quality

    Quality is the percentage of conforming parts produced compared to the total number of parts made. It indicates the proportion of defect-free products.

    OEE = Operating time / Total time × Actual speed / Theoretical speed × Conforming parts / Total parts

    Practical example of calculating OEE

    Let’s consider a machine with a total time of 16 hours per day. Of these 16 hours, it is scheduled to operate for 14 hours (opening time) and actually operates for 12 hours (operating time). It produces 1,000 parts per day, with a theoretical speed of 100 parts per hour, meaning it should produce 1,400 parts in 14 hours. However, of these 1,000 parts, 950 are conforming.

    Availability: 12/16=75%
    Performance: 1000/1400=71.4%
    Quality: 950/1000=95

    Thus, OEE = 75% × 71.4% × 95% = 50.9%.

    This example illustrates how each component of OEE contributes to the overall evaluation of the machine’s efficiency.

    Why OEE is crucial for industrial performance

    Continuous improvement and OEE

    OEE is a fundamental tool for continuous improvement in the industrial sector. It helps identify inefficiencies and target areas that need improvement. By focusing on the three main areas – availability, performance, and quality – companies can develop a global strategy to optimize their operations.

    Availability axis

    The availability axis concerns the time during which equipment is operational and ready to produce. High availability means that machines are less prone to unplanned downtimes, which reduces time losses and improves production flow. By monitoring availability, companies can better plan preventive maintenance and reduce downtime.

    Performance axis

    The performance axis focuses on the actual production speed compared to the maximum theoretical speed. Optimal performance means that the equipment is running at its full potential, minimizing slowdowns and inefficiencies. By analyzing this axis, companies can identify bottlenecks and adjust processes to improve production speed.

    Quality axis

    The quality axis evaluates the proportion of conforming products compared to the total number of products made. Maintaining a high level of quality is essential to minimize product returns and scrap costs. Monitoring this axis helps detect and correct production defects quickly, ensuring customer satisfaction and the company’s reputation.

    Case studies and recent examples

    Many companies have leveraged OEE to transform their operations. For example, a large manufacturing company managed to increase its OEE by 15% in one year through better maintenance management and process optimization. By focusing on continuous improvement through OEE, it not only reduced production costs but also improved product quality, strengthening its competitiveness in the market.

    Another example is a consumer goods manufacturing plant that used OEE to identify recurring quality issues. By analyzing OEE data, it implemented targeted training for its operators and adjusted its processes, leading to a significant reduction in production defects.

    These examples demonstrate how OEE can serve as a strategic lever for improving industrial performance by providing measurable data to make informed decisions and guide continuous improvement efforts.

    Tools and methods to optimize OEE

    Evaluation software and tools

    To optimize OEE, many companies turn to specialized software that allows them to track and analyze performance in real time. These tools provide custom dashboards, making it easier to visualize critical data such as operating time, downtime, and product quality. Some of the most commonly used software includes MES (Manufacturing Execution Systems) and CMMS (Computerized Maintenance Management System) solutions that integrate advanced features for OEE tracking and optimization.

    These tools help not only to collect accurate data but also to quickly identify the root causes of inefficiencies. By using this software, companies can easily compare current performance with set objectives and make data-driven decisions to improve their production processes.

    Digital transformation and technological tools

    Digital transformation plays a key role in optimizing OEE. The integration of advanced technologies such as the Internet of Things (IoT), artificial intelligence (AI), and data analytics allows for real-time monitoring of equipment status and the anticipation of potential failures. IoT sensors, for example, can provide valuable data on temperature, vibration, and other performance indicators of a machine, contributing to more effective predictive maintenance.

    Furthermore, automation and robotics technologies can reduce human errors and increase the speed and accuracy of production, positively impacting OEE. Digitizing production processes also improves traceability and resource management, which is essential for maintaining a high OEE.

    Strategies to reduce costs and increase efficiency

    Optimizing OEE also involves implementing strategies to reduce costs and improve overall efficiency. One common approach is the adoption of Lean Manufacturing methods, which focus on eliminating waste and continuously improving processes. By reducing non-value-added activities, companies can significantly increase their OEE.

    Moreover, continuous employee training is crucial to ensure they are fully competent in using equipment and new technological tools.

    Finally, analyzing historical data and regularly evaluating processes helps identify opportunities for improvement and implement effective corrective actions. By adopting a proactive approach and using the right methods and tools, companies can not only improve their OEE but also enhance their competitiveness in the market.

     

     

    FAQ – In brief :

    How is OEE Calculated?

    OEE is calculated by multiplying three key ratios: availability, performance, and quality. Each ratio is expressed as a percentage and reflects a specific aspect of equipment efficiency. The formula is:

    OEE = (Running Time / Total Time) × (Actual Speed / Theoretical Speed) × (Conforming Parts / Total Parts)

    For an accurate calculation, it is essential to measure each element correctly and take into account all time and quality losses.

    What is a Good OEE?

    A good OEE varies by industry, but generally, a OEE of 85% is considered excellent. This means the equipment is being used effectively and losses are minimized. However, achieving a OEE of 100% is rare and often unrealistic, as it would imply no downtime, performance losses, or quality defects. It’s important for each company to set its own goals based on its specific processes and constraints.

    What’s the Difference Between OEE and TEEP?

    OEE (Overall Equipment Efficiency) and TEEP (Total Effective Equipment Performance) are both performance indicators used to evaluate production process efficiency. OEE specifically focuses on the efficiency of a single piece of equipment by analyzing availability, performance, and quality. TEEP, on the other hand, considers the entire production chain, including logistical and organizational factors. Thus, TEEP provides a broader view of overall company efficiency, while OEE is more targeted at individual machine performance.

    How Do You Implement OEE?

    Implementing OEE involves several key steps. First, it’s essential to gather accurate data on running times, downtimes, and product quality. Next, you should use a tracking tool or software that enables real-time OEE calculation and analysis. It’s also important to train staff on the importance of OEE and how to optimize it. Finally, regular meetings to review performance and identify opportunities for continuous improvement are crucial to maximizing the benefits of OEE in the company.

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  • Everything you need to know about total productive maintenance

    Everything you need to know about total productive maintenance

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    Total Productive Maintenance (TPM) is a comprehensive approach to maximizing equipment efficiency. Total Productive Maintenance is a comprehensive approach to maximizing equipment efficiency by involving all employees in the maintenance process. By focusing on reducing breakdowns and losses, productive maintenance promotes organizational performance and productivity. It implements rigorous methods that increase quality and extend machine life, while reducing downtime.

    What is total productive maintenance?

    Definition and basic principles

    It’s a proactive maintenance management method, involving all employees, from operators to managers, in the management and maintenance of machines. The main aim is to reduce unplanned downtime and improve equipment performance by maintaining optimum quality levels throughout the production process. This approach eliminates losses due to breakdowns and inefficiencies.

    History of total productive maintenance

    Born in Japanese factories in the 1970s, this method was developed by Nippondenso, a Toyota supplier. Inspired by the concept of preventive maintenance, it rapidly evolved into a global equipment management method. The model then spread throughout the world, becoming an essential pillar of continuous improvement in many companies seeking to optimize their production.

    The pillars of total productive maintenance

    Case-by-case improvement

    Case-by-case improvement (Kaizen) is an essential pillar of Total Productive Maintenance. It involves analyzing production process data to identify and eliminate recurring or one-off problems affecting machine performance. Each improvement activity aims to reduce wasted time, breakdowns and inefficiencies, thus contributing to sustainable productivity gains.

    Autonomy

    Employee autonomy is crucial to total productive maintenance. Operators are specifically trained to carry out basic maintenance tasks on the equipment they use on a daily basis. This empowerment enables minor problems to be detected quickly, before they turn into costly breakdowns, while increasing team commitment and machine reliability.

    Quality maintenance

    Quality maintenance focuses on preventing defects by integrating control methods right from the early stages of production. The aim is to maintain a constant level of quality by identifying potential failures before they result in defects or breakdowns. This pillar reduces losses due to production errors and improves equipment reliability.

    Planned maintenance

    Planned maintenance consists in anticipating interventions on machines before they break down. By analyzing data on equipment uptime, companies can plan maintenance shutdowns at strategic times, minimizing production interruptions and guaranteeing business continuity.

    Preventive equipment maintenance

    This pillar concerns maintenance actions carried out right from the equipment design stage, in order to reduce future problems. The aim is to integrate maintenance into the machine design phase to guarantee reliability and ease of maintenance. This approach avoids unscheduled downtime and extends the life of equipment right from the start.

    Safety, health and environment

    This pillar aims to ensure that equipment maintenance is carried out in a safe environment for employees. By reducing the risk of injury and guaranteeing safe working conditions, it helps to improve overall workplace safety, while complying with environmental and health standards. This helps prevent accidents and boosts team efficiency.

    Why adopt total productive maintenance in your organization?

    Objectives and benefits

    Total Productive Maintenance achieves a number of crucial objectives for any organization: improving equipment performance, reducing breakdowns and production losses, while guaranteeing better product quality. Benefits include reduced downtime, optimized work processes and improved employee commitment. By integrating TPM, the company optimizes machine utilization and improves overall productivity and profitability.

    Implementing total productive maintenance

    Steps to integration

    Integrating Total Productive Maintenance (TPM) into an organization involves several stages. First, it’s essential to train staff, especially operators, to get them involved in the project. Next, equipment data must be analyzed to identify recurring problems. Finally, an improvement plan is implemented with the collaboration of the teams to eliminate breakdowns, reduce production losses, and optimize processes.

    Tools and resources required

    Effective implementation of total productive maintenance requires maintenance management tools, such as equipment tracking software and performance indicators. Dedicated human resources for employee training are also crucial to ensure that every operator can contribute to machine maintenance. In addition to diagnostic tools, it’s important to have a committed team in place to anticipate and resolve problems before they lead to unplanned downtime.

    Practical application examples

    In an industrial production company, this can take the form of regular training for operators in the day-to-day upkeep of machines. For example, the implementation of planned preventive maintenance helps to reduce production stoppages due to breakdowns. Teams are organized into dedicated workgroups, responsible for the quality of each piece of equipment, which considerably improves overall performance and reduces losses.

    The benefits of this method

    Reducing Downtime

    One of the main benefits is the reduction in unplanned production stoppages. By optimizing equipment maintenance, companies reduce frequent breakdowns. This helps to reduce downtime and maintain a continuous flow of production. Better machine management ensures increased availability, enabling the organization to meet production deadlines and customer needs.

    Improving overall productivity

    Total Productive Maintenance leads to a significant improvement in productivity. By implementing efficient maintenance processes and involving every employee, companies can eliminate unnecessary losses. Maintenance teams and operators work together to detect problems before they affect production. This proactive approach helps optimize resources and use equipment more efficiently, improving overall performance.

    Impact on customer satisfaction

    By reducing breakdowns and quality losses in the production process, it has a direct impact on customer satisfaction. Products are delivered on time, with consistent quality, reinforcing customer confidence in the company. Proactive maintenance helps avoid delays, ensuring that production targets are met while meeting customer quality expectations.

    Total Productive Maintenance FAQ

    What is the TPM method?

    The TPM (Total Productive Maintenance) method is a management system designed to optimize equipment efficiency by involving all employees in machine maintenance. The aim is to improve production performance and quality by eliminating losses and reducing breakdowns. This process enables the company to maintain a high level of productivity and efficiency.

    Who invited him?

    TPM was developed by Japanese company Nippondenso, a key Toyota supplier, in the 1970s. The project was born of the need to reduce downtime and maximize equipment productivity. Since then, the method has spread throughout the world, becoming a benchmark for many companies seeking to improve their overall performance.

    What are the main pillars of this method?

    TPM is based on several essential pillars, including case-by-case improvement, operator autonomy, planned maintenance and quality maintenance. Other pillars include safety, health and environment, and equipment preventive maintenance. Each pillar contributes to an overall approach to maximizing machine performance and minimizing breakdowns.

    What is autonomous maintenance?

    Autonomous maintenance is one of the pillars of TPM, in which operators are trained to take on basic maintenance tasks on their own machines. This includes activities such as cleaning, inspecting and tightening components. By empowering employees at this level, companies can reduce unplanned downtime and improve equipment reliability, while increasing staff commitment.

     

    Stay connected:

    Pour ne rien manquer de l’actualité de TEEPTRAK et de l’industrie 4.0, suivez nous sur LinkedIn et YouTube. Inscrivez-vous également à notre newsletter pour recevoir le récap mensuel !
    Ceci pourrait également vous intéresser :

     

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  • How can you reduce the maintenance costs of your machines while maintaining quality and performance?

    How can you reduce the maintenance costs of your machines while maintaining quality and performance?

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    The maintenance of your production machinery is an essential aspect of any production site. However, maintenance costs can quickly add up and become a major financial burden for the company. Fortunately, there are several ways to reduce maintenance costs. This will not harm the quality and performance of the machines. In this article, we will explore some of the most effective strategies for reducing these expenses. Although necessary, let’s avoid waste as much as possible!

     

    The method :

     

    Set up a preventive maintenance programme

     

    Regular preventive maintenance can help avoid costly breakdowns in your machinery. Potential problems need to be identified and repaired before they become more serious. By establishing a regular preventive maintenance programme for each machine, you can ensure that machines are regularly inspected and serviced. This will reduce your maintenance costs in the long term.

     

    Use machine monitoring technologies

     

    Machine monitoring technologies such as IoT sensors, diagnostic software and quality control systems can help detect machine performance issues before they develop into bigger problems. ProcessTrak, our dedicated process value monitoring tool, lends itself very well to this exercise. It is even more powerful when coupled with our Machine Learning. These IoTs can help predict potential breakdowns. This allows maintenance technicians to repair machines before they break down!

     

    Train staff in basic maintenance

     

    Training staff in basic maintenance can reduce maintenance costs by reducing the need to call in external service engineers for minor problems. By training your staff in basic maintenance, you can ensure that minor repairs are carried out quickly and efficiently, without having to spend money on sub-contractors.

     

    Planning maintenance during shutdown periods

     

    Scheduling maintenance during periods of downtime can reduce the cost of work by minimising the loss of production due to machine stoppages. By scheduling maintenance during holiday periods, you can minimise the impact of maintenance on overall production. This will reduce your costs associated with lost production.

     

    Use quality spare parts

     

    Using quality spare parts can reduce maintenance costs by reducing the frequency of repairs required. Quality parts are more durable and resist wear better than inferior parts. Although the purchase cost may be higher, this will enable you to produce for longer. That’s how you can reduce the impact of your maintenance expenditure.

     

     

    Monitor machine performance

     

    Monitoring machine performance can help to detect potential problems before they become actual problems. By monitoring machine performance, you can detect a number of things. Abnormal scrap generation, an increase in unplanned stoppages, or a slowdown in throughput. These clues can point to future problems.

     

    To sum up

     

    It is important to implement a preventive maintenance strategy to reduce maintenance costs. This strategy consists of regularly planning machine maintenance by carrying out regular inspections, replacing worn parts before they cause greater damage, and setting up a regular maintenance schedule to avoid unforeseen breakdowns.

     

    Finally, employee training is also a key element in reducing maintenance costs for industrial machinery. Well-trained employees are able to detect problems earlier, carry out minor repairs and perform preventive maintenance. In addition, well-trained employees can reduce the risk of errors and costly damage caused by the misuse of machinery.

     

    In conclusion

     

    Reducing maintenance costs for industrial machinery is essential to maintaining machine quality and performance, while reducing operational costs. By implementing a preventive maintenance strategy, choosing the right spare parts, using the right consumables and properly training employees, companies can keep their equipment in perfect working order while minimising maintenance costs.

     

    To keep up to date with all the latest TEEPTRAK news, visit LinkedIn or YouTube

    You may also be interested in

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  • 10 tips to improve the performance of your machines

    10 tips to improve the performance of your machines

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    10 tips for improve the performance of your machines

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    Machine performance is a crucial issue for companies. High-performance machines enable you to produce faster, reduce production costs and minimise downtime. In this article, we’ll be sharing 10 tips for improving the performance of your industrial machinery.

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    ☑ Tip 1

    Carry out regular preventive maintenance

    Preventive maintenance is a key element in keeping your machines running smoothly. It involves carrying out regular inspections to identify potential problems. You can then carry out the necessary repairs before a problem occurs. The benefits of preventive maintenance are many, including reducing unplanned downtime, improving production quality and increasing machine life.

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    ☑ Tip 2

    Calibrate and adjust regularly

    Industrial machines need to be correctly adjusted and calibrated to ensure optimum performance. They help to keep machines in optimum working order and minimise downtime. It is important to follow calibration procedures and check the results regularly.

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    ☑ Tip 3

    Optimise operating parameters

    Operating parameters such as speed, pressure and temperature can have a significant impact on the performance of industrial machinery. It is important to optimise these parameters to maximise performance and machine life. Manufacturers often provide recommendations for optimum parameters, and it is important to follow them. It is now possible to get help from the IOT to bring these indicators under control.

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    ☑ Tip 4

    Use quality spare parts

    It might seem obvious, but you need to supply your equipment with compliant parts, not ‘do-it-yourself’ parts. Spare parts play a crucial role in the performance and lifespan of industrial machinery. It is important to use quality spare parts to guarantee the reliability and performance of your machines. Cheaper spare parts may seem attractive in the short term, but they can lead to higher maintenance costs and extended downtime.

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    ☑ Tip 5

    Train your operators

    Operators play a key role in the performance of industrial machinery. It is important to provide them with adequate training so that they understand machine specifications, maintenance procedures and good operating practices. Proper training can help minimise operating errors, improve efficiency and reduce downtime.

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    ☑ Tip 6

    Monitor the performance of your equipment

    Monitoring machine performance is essential to identify potential problems before they become critical. Monitoring tools such as sensors and control systems can be used to track machine performance and detect early warning signs of problems. There are 2 dimensions to this:

        • Monitor process parameters to be alerted in the event of a deviation from one of the values
        • You can also monitor production rates in real time. This will enable you to react as quickly as possible in the event of stoppages.

    In both cases, this leads us to our 7th tip!

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    ☑ Tip 7

    Use cutting-edge technologies

    Cutting-edge technologies such as artificial intelligence, IOT and augmented reality can help improve the performance of your equipment. These technologies enable real-time monitoring, predictive maintenance and advanced data analysis to optimise your performance. You can benefit from a significant return on investment by using these technologies to improve the performance of your machines.

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    ☑ Tip 8

    Maintain a clean and organised working environment

    A clean and organised working environment can help to improve the performance of your machines. It reduces the risk of contamination and keeps equipment in good condition. An organised working environment can also help reduce downtime by giving workers quick access to the tools and spare parts they need.

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    ☑ Tip 9

    Plan maintenance activities

    Effective planning of maintenance activities can help you minimise unplanned downtime and improve the performance of your machines. Maintenance planning should take into account machine specifications, production schedules and recommended maintenance intervals. By planning maintenance in advance, you can minimise the associated costs and maximise the performance of your machines.

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    ☑ Tip 10

    Use quality lubricants

    Lubricants play a crucial role in machine performance, whether on machining centres or other equipment. Quality lubricants help to reduce friction and wear, extending machine life and reducing maintenance costs. It is important to choose lubricants that are adapted to the specifications of the machines and to respect the recommended oil change intervals.

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  • 5 levels of maintenance to put under the Christmas tree

    5 levels of maintenance to put under the Christmas tree

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    5 levels of maintenance to put under the Christmas tree

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    As the festive season approaches, manufacturers are taking stock. How productive were their machines this year? Among the plants surveyed, around 5% of unplanned stoppages were due to breakdowns or maintenance in 2020. For a third of them, breakdowns represent 20% of the causes of annual stoppages.

    The consequences can be serious, with delivery to the customer out of time, or worse: the stress generated by the need to make up for the delay can cause accidents…

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    The best way to avoid them: TPM

    TPM (Total Productive Maintenance or Total Productive Maintenance is a corporate culture based on LEAN Management. It promotes maximum efficiency in production equipment. Its aim is to achieve ‘0 accidents, 0 breakdowns, 0 defects’.

    The aim of this philosophy is to produce more and better by tackling waste (or Mudas). When applied to machines, this means seeking to maximise production time and ensuring that production is carried out at optimum rates while producing compliant parts. These are the 3 axes measured by the TRS: Availability, Performance and Quality.

    The main change is in the mindset, with cooperation between departments, particularly between production and maintenance. The maintenance technician will also become a technical adviser, working with the operators.

    TPM involves 5 levels of maintenance.

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    Level 1 maintenance or self-maintenance

    Level 1 maintenance is the first level of maintenance, and is preventive. The operator carries it out by following a standard or a checklist, and after training. It involves visual checks, greasing and simple measurements. It is carried out periodically and quickly, for example at the start of each shift or at the beginning of each day. The frequency should be defined in relation to the manufacturer’s data, the breakdown history or any FMEA.

    Level 1 maintenance involves the operator and increases his skills. They become capable of detecting abnormalities, vibrations or wear. At the same time, the use of 5S ensures that machines are clean and tidy. This saves time for the maintenance operator and means that any problems – such as leaks – can be detected more quickly.

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    Level 2 maintenance

    Level 2 maintenance is also part of prevention. It involves the periodic replacement of parts, or adjustments that can be made by following a procedure.

    This is usually done by maintenance technicians, although some operators who are committed, experienced and, above all, trained may be eligible.

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    Other maintenance levels (3-4-5)

    Other levels of maintenance usually require production to be stopped. Calibrations or adjustments may be necessary. In-depth knowledge is essential, and may be internal or external.

    At that point, the operator finds himself ‘technically unemployed’. The development of multi-skilling can certainly limit the loss of human time, but the availability of the machine is impacted.

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    How can you make the most of your time off?

    When the workshop is closed, maintenance time is outside production time. This is the time to carry out level three, four and five maintenance. In this way, these operations have no impact on production.

    What’s more, technicians and other machine operators don’t feel the pressure of a manager ready to do anything to save a few minutes and meet his targets. Be careful, however, not to overdo the maintenance, which would generate unnecessary costs. That would be a waste! But how do you know when the time is right for this meeting? And what if production doesn’t stop at the holidays?

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    Non-stop production

    If production doesn’t stop during the holidays, we no longer have a slot to carry out level three, four or five maintenance. Each stoppage will affect our availability and therefore our production. In this case, you need to choose the best time to work on your machines. Premature intervention is a waste of time. Conversely, neglecting the needs of the machine is a mistake. It can lead to poor quality, a breakdown or, worse still, endanger the people in the workshop.

    Thanks to the IoT, it will soon be possible to know the state of components inside machines, and at the same time predict the ideal moment for intervention. This will make it possible to maximise the use of production tools by limiting downtime. This is predictive maintenance.

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    In conclusion

    While your maintenance team is doing its utmost during the plant shutdown, isn’t it time to consider the impact of breakdowns on production? If you’re equipped with a performance analysis tool like PerfTrak, you’ll be aware of these figures.

    But are the LEAN tools deployed to process this information and improve productivity? And if you don’t have an analysis tool, do you have any idea of the cost of downtime for your production machines? We look forward to finding the answers to these questions,

    Happy holidays from the whole team at TeepTrak!

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  • How can you improve your machine performance with a dedicated monitoring tool?

    How can you improve your machine performance with a dedicated monitoring tool?

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    How can you improve your machine performance with a dedicated monitoring tool?

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    As a manufacturer, your main challenge is to achieve quality production with maximum equipment availability and maximum machine performance.

    Yet manual methods of measuring performance are still widespread, time-consuming and unreliable: it is estimated that they cause plants to lose between 5 and 30 performance points.

    In this context, the integration of a dedicated tool makes perfect sense and will become an ally in your Lean approach to improving the performance of your machines.

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    The different types of loss of machine performance

    The causes of loss of performance in an industrial environment can be very varied, but there is a list of the most common losses. You will find a non-exhaustive list below:

    Equipment losses

    • Losses due to breakdowns
    • Losses due to settings
    • Losses due to tool changes
    • Start-up losses
    • Losses due to microstops and idling
    • Losses due to underspeed
    • Losses due to defects and rework
    • Losses due to programme stoppages and workshop closures

    Labour-related losses

    • Management losses
    • Losses due to speed of execution
    • Losses due to line organisation
    • Logistics losses
    • Losses due to measurement and adjustment

    Material, tooling and energy losses

    • Energy losses
    • Losses due to tooling
    • Losses due to material yield

     

    TRS analysis with 16 TPM losses, Christophe Hohmann website

     

    From this list, you can carry out targeted data collection based on the various events that have led to a drop in performance and determine their source.

    Most manufacturers have an excellent understanding of the causes of efficiency losses that prevent their machines from reaching peak performance.

    In the majority of cases, these are “simple” problems, often poorly dealt with for lack of time, money or technical/managerial skills. So the problem is not in identifying problems, but in measuring them, prioritizing them and, above all, dealing with them in the right order of priority with the right corrective measures.

    How can we provide teams with simple, intelligible information to help them make decisions and support them in their efforts to improve performance? By providing them with transparency on the causes of the non-performance of their assets and supporting them in taking action to improve.

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    A dedicated monitoring tool to facilitate your improvement process

    A performance monitoring tool will enable you not only to quickly identify the causes of loss of performance, but also to implement the right improvement plans.
    The analysis of the sources of losses must be specific to your company. In fact, it is up to you to define the source of your event at the origin of the loss, for example maintenance, quality or managerial faults, etc.
    Only customisation will enable you to adapt and, above all, facilitate the use of the tool so that day-to-day actions change and generate more value for the company.

     

    Here are just a few of the benefits such a tool could bring to your organisation:

    For the operator : Allows automatic communication on stoppages, real-time knowledge of production rate.

    For the manager : Real-time status of equipment operation, simplified analysis, rapid suggestions for improvement.
    For maintenance: Analysing the causes of recurring losses will enable a maintenance system to be adjusted or defined.

    For management: Provide information that will enable better analysis of equipment load rates, and thus guide investment policy or team organization.

     

    All the members of your organisation will benefit from this data to implement an improvement process quickly, efficiently and transparently.[/et_pb_text][/et_pb_column][/et_pb_row][/et_pb_section]

  • What indicators should you use to measure the performance of your machines?

    What indicators should you use to measure the performance of your machines?

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    What indicators should you use to measure the performance of your machines?

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    To achieve the objectives of a Lean approach focused on machine performance, it is necessary to exploit all the data linked to machine performance and availability.

    In this article, we will look at a selection of indicators that can be used to analyse the productivity of your machines.

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    Maintenance monitoring indicators

    Machines need to be closely monitored so that maintenance departments know when to intervene and what the consequences of a repair would be in terms of lost time and therefore productivity.

    The performance of maintenance operations plays a major role in a company’s overall productivity, and this section looks at a selection of indicators that can be used to measure this performance.

    • MTBF – Mean Time Between Failure = Temps Moyen Entre Pannes

    Expressed in hours, the Mean Time Between Failure (MTBF) is an indicator that can be used to determine whether a piece of equipment is reliable.

    It can be a decisive factor in the decision to replace equipment if it is deemed too short, leading to repeated stoppages and consequent losses in performance and productivity.

    MTBF = Gross Run Time / Number of Faults

    • MTTR: Mean Time To Repair

    MTTR shows how much time is needed, on average, to detect and locate a fault and replace the defective part, and can highlight the need to find solutions to make maintenance operations simpler and faster.

    MTTR = Failure Time / Number of Failures

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    Machine performance indicators

    Here is a selection of indicators you can use to analyse the productivity of your machines.

    • Synthetic Efficiency Ratio – SER

    It expresses the company’s ability to use the equipment made available to it to the best of its ability, based on the time during which the equipment is given to production for use.

    It can find out how the equipment has performed according to 3 criteria:

    • Availability
    • Their performance
    • Quality

    Calculating the OEE

    The TRS breaks down into 3 rates:

    Availability rate – Do : This represents the percentage of opening time during which equipment is ready to work. Performance rate – Tp : This represents the percentage of gross operating time during which production is carried out at the planned rate.

    Quality rate – Tq : This represents the percentage of net operating time spent making good parts.

    TRS = Tq * Tp * Do[/et_pb_text][et_pb_image src=”https://teeptrak.com/wp-content/uploads/2023/06/schemas-TRS-02-1024×574-1.png” title_text=”schemas-TRS-02-1024×574″ _builder_version=”4.21.0″ _module_preset=”default” global_colors_info=”{}”][/et_pb_image][et_pb_text _builder_version=”4.21.0″ _module_preset=”default” text_font=”|300|||||||” text_text_color=”#000000″ text_font_size=”16px” global_colors_info=”{}”]

    TRS gives you an accurate picture of the efficiency of your manufacturing process and makes it easy to track improvements over time.

    • General Rate of Return – GRR and Economic Rate of Return – ERR

    The General Rate of Return (GRR) and the Economic Rate of Return (ERR) are less often used, but are just as interesting for a relevant analysis of productivity.

    The ERR provides visibility of your machine’s profitability in relation to its uptime over a specific period. This is the time actually spent producing quality over 24 hours.

    This rate also provides important information on the overall capacity of a machine to deliver quality production, enabling the company to refine its investment strategy.

    TRE = TU / TT

    The Overall Equipment Efficiency Ratio (OER) measures the level of efficiency of a piece of equipment in relation to the actual opening time of the workshop, i.e. the time used to produce quality over the workshop opening period.

    This rate can be revealing when it is discovered that it is necessary to add an extra team to achieve the expected production targets.

    TRG = TU/TO

    • True Downtime Cost (TDC) and percentage of downtime

    How much money does your company lose every minute or hour your machines are down? This is the question frequently asked when analyzing the production losses of a machine, but which unfortunately only arises when the machine breaks down.

    It’s important to remember that even a small percentage reduction in downtime can save your business millions of euros. So by calculating your cost of downtime and identifying associated improvements, you can demonstrate time and cost savings, as well as reductions in waste.

    • Using capacity

    The effective cost of owning and maintaining equipment is reduced when that equipment is used at full capacity. By measuring the output that is actually produced by your equipment and comparing it to what could be produced, you understand the efficiency of your operation.

    When your plant increases its capacity utilisation rate, it increases its efficiency.

    TeepTrak allows you to detect the on or off state of each piece of equipment. This detection will ensure the automated calculation of most of the indicators mentioned above. What’s more, this will provide you with significant support in terms of direct feedback on the influence of your improvement actions on your machines, and therefore better visibility of the monitoring of your Lean approach.

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  • What is Lean? How to make your project a success?

    What is Lean? How to make your project a success?

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    What is Lean? How to make your project a success?

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    Although Lean is now well known and used in the language of many business sectors, providing a synthetic and relevant definition of the term Lean remains rather tricky. In fact, despite its international spread following its introduction by Toyota in the 1950s, the concept of Lean is still fairly difficult to master and has little staying power in companies that try to deploy it.


    Lean is defined as an organisational logic and a management system designed to create value for customers, eliminating everything that is unnecessary within a process, such as waiting times, rework, overproduction, superfluous journeys… In short, everything that can be described as wasteful and penalises cycle times.

    The origins of Lean

    The term Lean was coined by James Womack and Daniel Jones (MIT) in 1980, following a study comparing Japanese automotive industrial performance with that of the United States and Europe.

    The production system set up by TOYOTA in Japan appeared to be the most efficient of any other industrial system. From the 90s onwards, this production system became the benchmark. Today, a large number of companies have defined their own system, but each time, it is a rewriting of the Toyota model.

    Lean objectives

    Lean has 3 objectives:

      1. Focus on customer expectations and the value to be created to satisfy them

      1. Improve your company’s performance by eliminating ‘waste’ in your processes

      1. Take account of employees’ needs by increasing fluidity, flexibility and agility.

    Lean’s initial focus was on industrial production, but it quickly spread beyond this area to cover all production support functions (methods, stock management, quality, maintenance), the development and industrialisation of new products, purchasing, etc.

    Today, Lean also covers the services sector and all the support functions such as HR, Finance, General Services and commercial functions (Sales, ADV, call platforms, etc.).

    How to make a success of your Lean project?

    Lean is a pragmatic and simple approach, and it’s probably because of its subtlety that it’s difficult to understand its deeper meaning and its full significance. Companies are often mainly interested in ready-to-use Lean tools such as :

      • The 5S,

      • Flow analysis

      • SMED

      • etc.

    Many companies try out the tools, but after a while the initial enthusiasm gives way to scepticism and disappointment, because the results are slow in coming and the changes take time to be reflected in everyday life.

    In other cases, resistance to change on the ground is virulent and the feeling of pressure takes over from the real improvement in activities. Integrating Lean must therefore be an integral part of every manager’s management method, as it will allow the approach to become part of the corporate culture, thereby limiting the risk of negative perceptions and confusion.

    Structuring the implementation of the Lean approach

    A company operates by implementing and improving a set of processes that enable it to obtain a result, an output, through a series of transformations:

      • Design process -> that transforms an idea into a marketable product or service,

      • Purchasing process -> that transforms a need into a product,

      • Manufacturing process -> which transforms a raw material into a finished product, etc.

    Everything is a ‘process’, and this is also true in the support or tertiary activities that transform data into information, information into decisions, etc.

    A project is the process of transforming an idea or a need into a result, hence the need for dynamic project configuration and interfacing with other processes, demonstrating our ability to work effectively across all customer functions.

    The importance of the management system

    In implementing a Lean approach, the manager must adopt the posture of a leader who motivates and supports his or her employees by their ability to increase their skills and solve their day-to-day problems independently. This requires a change in mentality and behaviour in managerial functions, based on the fact that ‘the most important person in the company is the one who produces for the customer’.

    Lean improvements are largely driven by operational staff, who develop a problem-solving culture, the aim being to support them so that they become more proactive and autonomous. These transformations must be decided, led and supported by management, with the following roles:

    Field team: Taking an active role on sites / Managing quality / Reporting waste / Respecting processes and standards

    Managers: Steering performance with teams and ensuring compliance with standards / Promoting problem-solving methods / Setting the standard for continuous improvement

    Management: Identify needs for improvement vs. strategy / Request new projects / Provide resources / Validate proposed solutions / Encourage and challenge results.

    Far from being a lever for redundancy plans, Lean management is a means of highlighting the good people who could become leaders, of giving meaning, autonomy and a permanent challenge that helps teams to develop their skills. What’s more, the method is implemented with all the staff, whose support and confidence in the objective being pursued are an essential condition for the success of a Lean approach.

    Based on several years’ experience in deploying Lean approaches within several CAC40 groups, we are particularly well aware of the impact that our solutions can have on your Lean approach. There’s nothing like combining new IoT tools with traditional principles to make this approach part of your corporate culture.

    From this observation, we have always kept in mind the need to develop simple but automated tools for non-value-added tasks, taking into account the technical and human constraints in the field. Our tool is not intended to replace a global production management system, but to complement it.

    We have carefully selected the functionalities, available in an ergonomic interface, that we think will be most useful to operators and their superiors in supporting your management system in achieving your performance objectives.

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