The objective is to increase production efficiency and line utilization
by using existing assets better. There is no single action (silver
bullet) that will achieve this, rather a combination of ongoing surgical
interventions. The system provides real time, accurate
and transparent data to facilitate these interventions.
The system will provide:
- Dynamic data highlighting irregularities in machine speed, line
control and overall line function according to its designed V-Profile.
Functioning like a production line oscilloscope, the primary objective
of this data is to provide technical staff with accurate intelligence on
exactly where and what intervention is needed. The key here is to
balance the line so it performs as a single unit, each machine in
harmony with the other.
- The HMI (Predictor) located at each major machine will automatically
prompt the operator to select a cause and estimated downtime when his
machine stops and it is identified as the constraint machine on the
production line. Although downtime is always viewed as a negative,
communicating this downtime to other operators allows them to capitalize
on the event by stopping their machines for minor maintenance
interventions. Their stop will have no impact on production line
efficiency, utilizing productive downtime is a positive.
- The "real" downtime and machine stop (cause) data captured by the
Predictors provides maintenance staff with a valuable tool for surgical
intervention, most of which can be accommodated during productive
downtime opportunities at no cost to line efficiency.
- To assist with rapid intervention, the Predictors and GlobeLive
management software facilitates real time bi-directional text messaging.
There is no cost associated with message communication across the
proprietary wireless network. Coupled to this the system comes standard
with a quad band GSM capability (texting mobile phones), however, local
network costs will be applicable. Messaging radically reduces response
times to critical or regular production events.
- Hard copy reporting. The GlobeLive management software can generate
both an Engineering report or Production report for any time period of
interest, no data input is required. The user simply selects the period
of interest and prints the report. Reports are detailed and cannot be
edited, they provide a wide range of information including components of
OEE, TPM and other important KPI data. Hard copy reporting radically
reduces time spent writing manual reports by Production and Engineering
- Production recording. The system automatically records
every aspect of all production activities to a one second resolution.
These recordings are automatically saved by shift. The users can select
a recording and "play back" a specific production event which can be
viewed in real time or accelerated time. All E-stop activities are
automatically bookmarked in the master recording. The user can also
insert bookmarks commenting on events as they occur. A full eight hour
shift recording only requires 2-3 Megabytes memory space, meaning they
can be emailed complete with bookmarks. The GlobeLive software maintains
all its functionality during playback mode. Production recordings is
another global first introduced by us, it obsoletes
traditional server type database archives.