Facing growth by increasing the OEE
An enormous production increase of Whirlpool, a manufacturer of large househould appliances, longs for an efficiency increase of the production facilities. Herefore, an Overall Equipment Effectiveness Tool of WERKSREVOLUTION paves the way.
Whirlpool Slovakia, Ltd.
PLANT: Poprad, Slovakia
ROLE: Manufacturer of top- and frontloader washing machines
PERFORMANCE: 2.4 million parts / day (2016)
WORKFORCE: 1,400 employees
The starting situation
Production increase longs for higher efficiency
Due to an enormous production increase in the last years, Whirlpool has to enhance the efficiency of its production facilities. For this, real-time data on utilization and performance of the production lines and machines is mandatory. Previous paper-based reporting is no longer able to meet the requirements in case of quality and speed. Therefore Whirlpool is looking for a reporting system which covers the following characteristics:
- Automatic collection of performance information from facilities (intervall < 1 sec.)
- Processing of machine data to KPI
- Simple visualization of facilities' utilization and efficiency
- Easy and quick reporting
- KPI monitoring and evaluation
Implementation of an oee-tool within 3 months
After a pilot stage in 2014 an Overall Equipment Effectiveness Tool (OEE) is implemented at 13 machines and 2 production lines one year later. Via an interface the system is connected to the ERP-System of the customer (ERP HANA). The data interchange with the facilities and production lines takes place by means of a PLC via OPC server, OPC client, MOXA converters and PowerMeter.
With the gathered performance data the manufacturer can - among other things - identify and analyse the main reasons for downtimes and take first measures to enhance efficiency. Due to real-time collection of data, effects of such measures taken are directly visible.
Continuous efficiency increase since 2014
Since the implementation of the system the Overall Equipment Effectiveness is constantly increasing. This is the result of the following optimizations:
- Reduction of time to fix of machines (as consequence of online monitoring)
- Decrease of unplanned production stops
- Reduction of direct and indirect costs associated with poorly functioning equipment, inferior quality and excess waste
- Discovery of bottlenecks in production
- Storage of OEE data for future analysis
- Comparability of OEE by task, workstation, shift or day
- Real-time tracking of product and process quality for continuous improvement