Dashboards for data based decisions
Jenő Csanaki Opel Szentgotthard Ltd. Unit manager, Machining Content
About OPEL Szentgotthard
Planning - Tool set - Execution • Business environment • Data – Measure - KPI • Data processing, forums • Reports
Results
Layout & capacity
1. Family1 engine plant 7 2. Flex engine plant 2 22,500 m 2 5 8 65,426 m 630,000 unit per year 4 645,000 unit per year
9 6 1 12 2 14 11 10
13
3 13. Transmission 4-5. Offices Remanufacturing 6. Outbound 1,100 m2 Transportation Hall 7. Warehouse 3. Cylinder-head plant 11,700 unit per year 8. Energy centre 2 9. Truck gate 15,500 m 10. Personal Entrance 2 625,000 unit per year 11. Social Building 12. Main Entrance / Offices 13. Reman 14. Knowledge Center Cars with Family1engines
Chevrolet Aveo/Sonic Chevrolet Cruze
Opel Corsa Opel Astra NB Chevrolet Trax
5 5 Opel Zafira Opel Insignia Opel Mokka X Cars with Flex engines
Opel Mokka X
Opel Insignia Opel Zafira Opel Astra Chevrolet Equinox
Chevrolet6 Cruze Chevrolet Malibu Opel Adam Opel Cascada 6 Flex machining lines & capacity
Indirect store Coolant Block
CRK1 CRK2 CBL1 CBL2 CBL3 MDE MDE/SG SGE MGE SGE 275 K/Y E (Alu) MGE (Cast MDE 280 K/Y 275 K/Y Iron) (Alu) 100 K/Y 180 K/Y
Hot Test
CHM1 Existing AssyAssy1
Plant crank SGE / MDE MGE/SGE
180 K/Y 285 K/Y (+ 85 K/Y)
Head Sub Coolant Logistic CHM2 AssyAssy2
CH2 Fam1 SGE / head MGE MDE MDE
100 K/Y 280 K/Y 275 K/Y (+95 K/Y)
Head Sub Coolant
New Plant/ Extension Example: Cylinder block machining line 3 Throughput- Planning
As a function…
Throughput f a,b,c,d,...,t
a: # of characteristics, b: # of machines, c: # of spindles(stations),
d: fd(share of characteristics between operations), e: fe(conveyance), f: ff(cycle time), g: fg(measurings), h: fh(planned, unplanned tool change), i: fi(interventions by operators), j: fj(breakdown), k: fk(impact of other machines, gantries, conveyors, adapters,…), l: fl(types, type changes), … Data Information Manufacturing process visualisation
Component Process production
Measure Produced parts
Uptime KPI
Layered reporting
Visualisation Processes KPIs
Uptime=NetOutput/(ScheduledHours/CycleTimepurch) [%]
SAT=Output/(RunningTime+Downtime) [JPH]
Supply chain& Logistics IT systems
Uptime
Energy & Supplier quality Utilities
Maintenance
SAT: Standalone Throughput Uptime Cost
Uptime Regular auto-identification Bottleneck Quantity losses Downtime, duration & frequency
By operation Cycle time By type During type change
Material Scrap Production
Rework Touch Suspect Data management, BI
DATA - DATA PROCESSING – REPORTS
Requirements • Proper data quality in time • One data once entered • Tracking changes in time (target changes) • Be capable to • aggregate • identically defined measures • Fast response • Layered reports • Shared BI • Sharing Business intelligence and OLAP
„Business Intelligence is a set of methodologies, processes, architectures, and technologies that transform raw data into meaningful and useful information used to enable more effective strategic, tactical, and operational insights and decision-making.” Evelson, Boris (21/11/2008) Multidimensional data structure OLAP cube
Machines
Time
Product type Data sources, systems
PMC TL, SL
CMM report Flexnet Qs-Stat OLAP Tabular System structure
Data Measures, KPIs, BI Reports
Special Browser OLTP Data reports OLAP Database Warehouse Shiftreports Cubes
Scheduling PMC MGO Flexnet PAS Dashboards Shared BI
ME MySQL FACS Schneider AVL Data (Flex Assy) Energy (Hottest) Collection Mgmt Report structure
Production area
Shared BI Frequency ReportingShared BI –examplesnew report
Web based reports Weekly report
Shared BI – new Production report dashboard Systematic forums & reports PMC Daily production Daily meeting TIP BN (SAT) ranking
Weekly Weekly production Shift meeting TIP Reports Weekly
Uptime action report plan update
Weekly production TIP meeting Monthly Monthly Cost management BPD review review report
Manuf Staff Mtg, >Monthly, LRP, CIP plan Cost Annual PPRM TIP: Throughput Improvement Process report BN: Bottleneck SAT: Standalone Throughput=Output / (RunningTime+Downtime) LRP: Loss Reduction Project WEB interface shiftly, manual supported by PM&C on-line
PM&C bottleneck (SAT) ranking ReportingWeb basedexamples
Web based reports Weekly report
Shared BI – new Production report dashboard Shared BI, database connections Daily reports ReportingProductionexamplesdashboard
Web based reports Weekly report
Shared BI – new Production report dashboard Weekly reports ReportingWeekly reportexamples
Web based reports Weekly report
Shared BI – new Production report dashboard Monthly reports
Action plans Other reports
Time from operator call to maintenance arrival Uptime improvement result Cost developement 2015 vs. 2016
Scrap cost THANK YOU FOR YOUR ATTENTION!