Unit 8 - Assessment and packaging line performance Flashcards
What is the purpose of efficiency reporting?
a measure to evaluate the productiveness of a machine or production line. NOT peoples performance.
OEE (Overall equipment effectiveness ) is a tool used to analyse equipment performance, accounting for losses due to availability performance and quality.
What does aggregate OEE measure?
the time that the line is required to run at full speed divided by the overall time that is available to run the line.
It is a straight division of the run time at full speed equivalent by the total time available.
Total time (hours available in week)
Why is line/process OEE the most important from a packaging line point of view?
As all factors that impact line performance can be measured and, more importantly influences, therefore all aspects can be improved through analysis and action.
How is line OEE calculated?
By taking the time required to produce all required cases while running the line at full speed and dividing this by the scheduled time as shown.
What is line efficiency and how do you calculate it?
Is the measure used to gauge how effectively a line is running when it has product run but no activities due to take place such as change over or tea breaks.
Efficiency =
Run time at full speed equivalent
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Planned time available
Never used in isolation as its misleading
What does OEE waterfall used to measure?
It represents the performance on a packaging line. Shows where issues have occurred that may require further attention.
Problem solving technique.
What is a “V” curve?
It’s produced by using the possible speeds of each piece of machinery.
Which allows managers to set optimum running speeds at the line for each machine.
On a line, what which machine would determine the balanced speed?
The filler. This all depends on pack size on which is the fasted and which is the slowest.
What are some of the problems that could occur if the line speed is not at a specified rate?
A palletiser that runs over speed could damage pallets or glass.
A bottle rinser that runs over speed could reduce the time that bottles are blown leading to dirty bottles.
A filler that runs over speed could result in a higher number of rejects due to underfilled bottles.
A labeller that runs over speed could result in “angled” labels.
A packer that runs over speed could result in label damage on the bottles.
What does accumulation solve?
It helps smooth out periods when a machine could potentially be starved of product due to a slower running machine either up or downstream.
Can be expensive to build the line its self.
For higher speeds accumulation is vital in order to give an effective line balance.
How are losses incurred on the production process?
When tanks are filled and emptied, its inevitable that there is some loss because of liquid left on the side of the vessel. (Wetting loss)
Spirit remains in the pipework on the completion of transfers from vat to vat or vat to line. Called Transfer loss.
Filtration losses are made because of the spirit that remains in the filter.
Packaging spirit losses are made when packs are overfilled or spillages or breakages occur.
What is the way to measure losses?
To compare the volume before and after a process.
What are the 3 key areas where spirit losses can impact the operation:
Financial - spirit waste is very costly to drinks packaging businesses with £m’s each year being lost.
Service - when spirit losses are excessive, the amount of liquid required for a customer order can be compromised and as such the number of cases required may not be met, leading to customer order misses or loss of revenue.
Legislative - spirit is tightly controlled by businesses as guidelines from HMRC require regular reconciliations to ensure that all relevant taxes i.e VAT are being paid. Where losses are evident, fines to be imposed duty charges levied and loss of reputation.
How can you prevent spirit loss?
Ensuring all product is properly flushed through at a completion of transfer.
Plant maintenance and elimination of leaks.
Action taken to reduce package breakages.
Strict control of fill heights
Adhere to quality checks and procedures on line
What are the 3 key areas where material losses can impact the operation:
Financial - material waste is costly to businesses.
Service - when material losses are excessive or unplanned, the amount of dry good required for a customer order can be compromised and as such the number of cases required may not be met.
Environmental - the more damage to dry materials that leads to disposal the more impact it has on the environment.
