Increase in system efficiency 

With ifp consulting for efficient and reactive production.

The way to high investment efficiency 

Disruptions become routine

Systems with long setup and idle times lead to high costs with low production. An increase in plant efficiency is the prerequisite for implementing lean processes.

Low system efficiencies mainly occur in systems that have been operated for a long time. As a result, small changes that lead away from the optimal setup process or brief malfunctions are transferred to the routine by the plant managers and are therefore not perceived as a serious cost factor.

Systems are operated at maximum speed because the machine has not been adequately maintained and cannot withstand the load or because possible control mechanisms are not designed for the correct speed of the system. Quality problems can often be traced back to processes that can be improved or insufficient maintenance.

However, even entirely new systems can show a low level of efficiency if the customer’s needs cannot be properly met or if the logistics and production concepts are not coordinated with one another.

The overall system efficiency is defined by three factors:

  • Availability factor
  • Power factor
  • Quality factor

These factors are mainly influenced by the Six Big Losses:

Failures -> Loss of availability due to disruptions or failures in the production process
Setting -> Loss of availability due to set-up time and tool settings
Micro Stops -> Loss of performance due to frequent downtimes of less than three minutes
Loss of speed -> Loss of performance due to production below the possible maximum speed
Scrap when starting up -> quality loss due to errors/problems when starting up
Scrap during production -> quality losses during normal operation (e.g. due to defective machine parts)

We’ll support you in increasing system efficiency

  • Breakthrough project – first increases in efficiency within a few weeks
  • Implementation of OEE and benchmarking – analysis and holistic evaluation of production and logistics
  • Workshops to develop the optimal order planning – simulation of the order planning and the resulting system availability
  • Recording and analysis of malfunctions/quality problems
  • Consideration of the capacities of several systems and elaboration of the ideal machine utilization in the overall picture
  • Involvement of the employees in the system to guarantee a generally accepted and long-term increase in efficiency
  • Reduction of the set-up time thanks to a storybook for set-up that is tailored to the system

Success factors

The retrofitting of older systems to bring them back to the current state of the art offers further aspects for increasing the system efficiency through constructive measures. For example, an effective and well-organised TPM can prevent unexpected downtimes, which reduce efficiency. Furthermore, continuous monitoring of the system and its KPIs is an important tool for directly recognizing any deviations from the optimal performance and taking countermeasures. For this, a powerful performance control is necessary to be able to monitor and evaluate all processes live.

How does plant inefficiency come about? 

Sometimes minor deviations from the optimal state add up and lead to long set-up and downtimes, which in turn result in low availability of the systems.

In order to be able to react to customer requests at short notice, capacity bottlenecks due to low system utilization must be avoided at all costs.

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