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!.