Having been approached by a major UK retailer to assist in their pursuit of improved productivity, we engaged our ’10 Steps to Productivity’ using LineView and set about a carefully planned project to deliver the required outcomes.
This project included multiple production lines (across the UK) where productivity, reliability and performance across sites were a clear concern for the business. The organisation needed to quickly identify where information was either being collected manually or missing, and automate data collection in those areas before identifying the six big reasons for loss of productivity.
This information was then presented in a format whereby management, operations and line staff were able to analyse, view and take appropriate action.
We installed sixteen main LineView XL800 systems in the abattoir, situated at the end of each line.Using this method of deployment meant that all the production line staff were always engaged and in sight of the boards.
The system was installed on each of the following sections within the abattoir:
- Primal Cutting Pork Boning
- Pork Packing MultiVac
- Pork CryoVac Packing
- Large Spider
- Small Spider
- Hind Quarter Beef Boning
- Fore Line Beef Boning
- Beef Line V95 CryoVac
- Pig Abattoir
- Beef Abattoir
- Pork Curing MultiVac
- Pork CryoVac Packing
- Curing 2 Pujolas
- Beef Dispatch 1
- Pork Dispatch 1
- Pork Dispatch 2
After an initial period of testing, it was found that in many instances targets had either been set too high or too low, so revised targets were put in place and uploaded to the system.
After an initial period of testing it was found that, in many instances, targets had either been set too high or too low so revised targets were put in place and uploaded to the system.
A baseline for improvement was established over four week period, during which all sections of the OEE formula were monitored and recorded both by shift and by product.
Taken as part of the DRM (Daily Review Meeting) process, this information was then translated into a series of actions designed to improve productivity.
This graphical representation is what you will see when you start to analyse the LineView XL800 dashboard. Green shows the line running, red down, yellow standby and blue setup:
The graphic below is what you see when you start to analyse the LineView XL800 dashboard. Green shows the line running, red is down, yellow is standby and blue is setup:
The top grey bar indicates a period of one day whilst the lower grey bar shows two specific products separated by the blue bar indicating a period of setup.
Using the LineView XL800, the client discovered the main reasons for loss of productivity. From which, the biggest causes of lost production were then identified.
It quickly became clear that the reasons for lost production & downtime had never been accurately recorded. With the implementation of the LineView XL800 system, recording of downtime became not only accurate but also consistent. Having examined the six main reasons for lost productivity, the following issues were identified and resolved:
Fore and hind quarter beef boning
Having set the break times into the system to the appropriate duration, it was found that (on average) these times were being exceeded by a period of at least 15 minutes per break. If the line did not return to a run state after these breaks, the system correctly recorded this time as “downtime”.
The LineView XL800 showed that the reason for this lost time was due to operatives waiting in line to be issued with clean knives prior to their return to the line. The client subsequently implemented a new system of issuing knives, which led to an almost 10% increase in productivity on an eight hour shift.
Pig abattoir, primal cutting pork boning, and pork MultiVac
On evaluating the “Big Six” in the pork department, it was found that the lines were stopped completely when an unidentified or unnoticed abscess on an animal had burst on the line. This caused the entire line to be closed for an unforeseen deep clean. With this knowledge further training was delivered to the staff in the abattoir, and a program of scheduled review meetings with farmers was put into place, in order to increase abscess detection.
As with the beef lines, the same knife issue procedures that were implemented soon saw almost a 10% increase in productivity on an eight hour shift in the pig area. Serious issues were rapidly found with the Pork MultiVac and packing lines, which could be “waiting” and “down” for nearly four hours per day due to lack of product. These times were quickly reduced by working more closely on planning and scheduling.
The results from the LineView XL800 identified the biggest losses, adding value to the DRM. Subsequently corrective measures were put in place to reduce these downtimes in the pork department. Overall labour losses were reduced from £9,500 per week to an average of £500 per week.
Using the LineView XL800 to generate barcodes, which were the cause of various reasons for downtime, the stoppage times were identified as coming from a certain section of the line which had been jamming and tripping out. Working alongside the Engineering team and the machine manufacturers, breakdown times were substantially reduced. Downtime on the lamb lines was reduced from an average of 35 minutes a day to (a staggering) zero.
8% increase in productivity through reduced knife waiting times.
Lamb line breakdown times reduced from 35 minutes a day to zero.
£9,000 per week in measurable savings and an overall increase in productivity.
Email us if you’d like to find out more about how we could help improve OEE using LineView technology in your organisation.