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Westfalia Presstechnik, supplier for the automobile industry, uses easyOEE to optimise existing production processes.
To see how quick and simple it was to set up easyOEE and to learn of the benefits it brought the company, have a look at this 3-minute video:
Click on the image to view the film (in german).
VION's first experience of automatic data capture was with the immediately deployable productivity measuring unit easyOEE. They subsequently decided to upgrade to the MES system FASTEC 4 PRO:
"We are very pleased. Around one year ago, our OEE values were only 35%, compared to the current 60%. Thanks to the increased transparency we have, we can now react in good time to malfunctions that occur in production, as well as being able to better plan our operations – stress is a thing of the past here.
If anything unusual happens during the production process,we are able to react immediately and in a targeted manner. In addition, everything is recorded in detail and documented in a way that allows it to be analysed, which means that, through regular evaluations, we can achieve ongoing process optimisation."
Dirk Kirchner, Production Manager at VION Convenience GmbH
Sartorius Stedim Plastics has seen someclear advantages through using the MES system FASTEC 4 PRO:
- Increased productivity
- Alarm system with escalation management
- Reduction in errors through automation of the previously error-prone label printing system
- Automatic entry of stocks to the PPS system
- Very quick acceptance by the machine operators
With the introduction of easyOEE, we have been able to make the production process transparent. It was important that the employees did not interpret this desire for transparency as a way of "monitoring" them but instead that they realise quickly that analysis of the reasons behind malfunctions is necessary before corrective action can be taken.
OEE evaluations and analyses of reasons behind malfunctions are regularly made available for discussion to the system and maintenance employees as well as to foremen. In one of the three systems equipped with easyOEE, this leads to an OEE increase of around 4 - 6 % and corresponds to a pay off period of only a few weeks."
André Nikolaus, Head of Automotive Operations Scheduling,
SAMAG Saarfelder Werkzeugmaschinen GmbH, Saalfeld
November 2010
"With easyOEE Portable GSM, we have found just the right system to evaluate and optimise our different machines.
By now, we are also using it externally to gather first-rate data from companies with which we have good relations.
What we really like about the device are the unlikely high-performance configuration options. easyOEE can therefore be very easily programmed for a wide variety of situations."
Torsten Schlegel, CIP Coordinator, Alfred Ritter GmbH & Co. KG
Extract from the user report:
"With the now effective monitoring of the production processes that we have in place, we can detect errors and malfunctions considerably better and earlier than before. We are able to counteract unplanned downtimes in a targeted manner. In addition, we how have precise planning times at our disposal too. In this respect, we are see seeing significantly more transparency and flexibility as well as an increase in productivity. Against this backdrop of having 'a living, expandable system' for effective productivity increase at our disposal, we are looking forward with confidence to the future."
Kai-Uwe Harms, Head of Manufacturing, Packaging Technology and Visual Controls athameln pharmaceuticals GmbH
"In February 2009, we decided to rent the
easyOEE Portable system for three months. After just two days, the device arrived by post and I was able to put it into operation.
The start-up was easy and went very quickly and smoothly. Within two weeks, we were able to optimise the configuration of the device and adapt
it to meet the conditions on the line. The support staff at FASTEC were there to provide fast, professional help throughout this time.
Even during this early phase, we were able to see that we could drastically and immediately reduce the production losses on the line (which previously manifested themselves in the form of brief interruptions).
Over the course of the next few weeks, easyOEE became an indispensable tool, so much so that we can now say that the rental option was a complete success for us."
Paul May, Metsä Tissue GmbH, Kreuzau
"I have collected the following statements from employees who have been working with the easyOEE system on our pilot line since May 2008:
- Short period of adjustment and intuitive, simple operation
- Concentrates on what's important
- Clarity
- Flexible, customer-focused use
- Good visualisation options and modes of evaluation
to support processes of improvement - The option to enter free text for malfunction causes not stored
- Option to correct data
- Excellent service from FASTEC
- Real-time data capture versus retrospect
All these advantages have, almost entirely of their own doing, together with having the right team in place, led to an improvement of 10% in the OEE on this line and have persuaded us to equip more production lines with the easyOEE system."
Dr. Holger Schoen, Environmental & Lean Management, Bausch & Lomb, Berlin
Extract from user report and technical article:
"We produce up to 8 tonnes of food every day using FASTEC-controlled systems. This equals roughly 22,000 meals. The way the system has simplified our work means that we never want to be without it. (...)
The consistent product quality desired is achieved without any problem. The initial scepticism of the employees abated very quickly after the impressive results became clear and after their motivation grew as a result of the somehow more relaxed working environment brought about by the system's introduction.
Ewald Haupt, Head Chef at the "Cook and Chill" department at Sander Gourmet
"We have ascertained that new formulations resulting from our development process or adjustments to existing formulations can be incorporated very easily. Only two or three runs are required and the formulation is ready."
Sven Lüttgens, Head of Production Planning at Sander Gourmet
" Thanks to the introduction of easyOEE at five core shooters, we have, for the first time, been able to collect and evaluate precise information on production times and down times.
These discoveries allowed us to to take targeted action on improving performance and reducing down times.
We now plan on extending the easyOEE system to more machines and systems. We look forward to further effective collaboration with FASTEC and its staff."
Wolfgang Brugger, Head of Planning, Core Production, Moulding and Casting,Guss Komponenten, Hall in Tirol
"Before we introduced easyOEE, our employees had to frequently make paper notes. The values obtained in this way were then transferred into Excel and served as a foundation for creating evaluations.
Since easyOEE was introduced, the evaluations required are available in a timely manner in electronic form, which means we can react faster to any problems that may arise."
Christian Henkelmann, Head of Door Systems AssemblyBrose (Sindelfingen plant)
"We have been using the easyOEE system for six months now.
Particularly beneficial to us is the malfunction notification by SMS. Because of the large demand for our AIDS quick test, we were compelled in recent months to produce the product round the clock in ghost shifts.
Thanks to the SMS notification service from easyOEE, we were able to react to malfunctions very quickly, even during these kind of shifts, which gave us several days of "additional" production time. I would like to once again thank FASTEC for all its help."
Bernd Kölz, Trinity Biotech, Lemgo
"The systematic capture of the OEE indicator plays a major role within the context of our GPS (Global Performance System).
We were pleasantly surprised at how quick and easy it was to install easyOEE and how the software could be used almost intuitively.
The simple and convenient configuration was of particular importance for us and convinced us that we could use easyOEE at different machines within our plant. The comprehensive evaluations allowed us to quickly replace our gut feeling with hard facts and to define measures that needed to be taken for the problems identified."
Frank Lander, GPS Trainer, ZF Sachs AG, Bielefeld plant
"After using the FASTEC system for around three years now, we can say that we are benefiting in particular from the parts tracking feature in the engine room. This gives us a quick overview of the current production status and allows us to take action quickly in order to countersteer any problems that crop up. Search times have been minimised and general employee satisfaction has increased as a result of the improved internal flow of information.
Since we began keeping records, we have witnessed a performance improvement of up to 15%."
Alexander Schmeing, Managing Director, Holztechnik Schmeing GmbH & Co. KG, Ahaus
"We have been using the FASTEC system for four years in our plastic moulding plant.
By now, the system is in place at over 80 machines here.
The system is doing great work for us. Through improved monitoring of our machines for example, we have been able to realise productivity reserves of between 10% and 20%. In addition, we were able to reduce cycle times by a value in the two-digit percentage range.
Through systematic documentation of the reasons behind malfunctions, we were also able to optimise our tools."
Dieter Henke, Henke Beschläge GmbH + Co. KG.
