Mark Hanley, Worldwide Performance Indicator Program Lead at Kraft Foods,
will describe some of Kraft's experiences with OEE measurements at the March 31
Packaging Automation Forum, sponsored by Packaging World and Automation World. A
recent conversation with Hanley yielded these observations:
• Applying OEE metrics to a new packaging line helps guide engineering to a
better understanding of how machines need to be balanced, changed, or have their
software tweaked before the new line can become fully functional. We had a case
once where a line was installed for a new beverage product and it just wasn't
running right. After a deep dive into the downtime data that we were collecting,
our team discovered that the machines were not balanced due to the PLCs not
working in concert. Through programming changes efficiency was increased to a
point where the line actually exceeded the original start-up curve.
• Displaying OEE data on the plant floor provides plant floor personnel with
the information they need to make immediate process improvements in terms of
getting more product out the door. The system provides the Operators and
Mechanics with the information they need to make improvements, and then instant
feedback on the results of their actions. At another level, OEE and its
Components are extremely useful to our continuous improvement teams. This data
usage is more a matter of long-term planning and fostering the growth of a
continuous improvement culture.
• Based upon a 24/7 work week, world class OEE is considered 85%, and the
industry average is probably in the range of 81%. At Kraft we are at about 75%.
We're moving ahead, setting moderate goals - it is far easier and usually
cheaper to go from 60% to 65% OEE than it is to go from 80% to 85%.
• OEE has a long history at Kraft and has gone through an evolutionary
process. First it was a record-keeping system done manually then entered into a
web based reporting tool. Once sufficient PLC and Network structure were in
place, Information Systems (IS) worked with Engineering to automate the data
collection. The next step was to evolve the tool from being a Plant-based tool
into Web-based tool. IS did an excellent job of putting together the framework
and backbone of the system. But when it got down into the plant/line level,
things didn't always go so well. We assembled an OEE Core Team to be the Client
Owners of the system, providing a focused effort to improve the system and be
the voice for the plants in North America. A Plant OEE Champion was identified
in each facility whose responsibilities included speaking for the plant in
matters on the OEE system, owner of training for their plant, and keeper of the
work practices for data accuracy. The information gained from this process has
been integrated into our Lean Manufacturing Processes, Production Planning, and
Maintenance Planning. Over time we modified how data was collected and
transferred based on a clearer understanding of work practices in the plants.
Ultimately we arrived at the list of work practices that will guarantee good,
accurate data.
For more information on the Packaging Automation Forum, including registration details, contact events manager Adriene Cooper at [email protected].
