In our efforts to improve performance, the more
opportunities we have to learn, the better. In addition to analyzing
what has 'gone wrong', we can learn a lot from studying what has
'gone right'. The key is to understand why
things went so well.
of the many features of the new Holistic
Data System (HDS) from HMC
is the ability to analyze production significantly above the target
level, as well as performance significantly below that level, in
any given production interval. By collecting information on what
circumstances enabled extraordinary production, we can learn what
parameters, materials, crews, maintenance procedures or a variety
of other conditions have a positive impact on performance. These
exceptionally-good hours of production can be analyzed separately,
but in a similar manner as the below-trigger level hours, enabling
us to identify trends and patterns that we can learn from and try
to replicate more frequently.
Focusing on successes has some additional benefits:
someone why things went well tends to elicit very open
and honest responses
what factors seem to have a positive
effect on performance can help us identify
training and maintenance opportunities
from your successes conveys a positive message, is consistent
with the Holistic Manufacturing philosophy and is an important
element in 'continuous learning'
The ability to analyze above-target performance
is one of many new features in the new HDS
from HMC which
will be available at the end of Q1 of 2004. Stay tuned for more
information on this commercial grade system, or contact
HMC for further details.
The new Holistic
Data System (HDS) will have
all the benefits of the Hourly Data System that HMC has developed
and installed in numerous client facilities over the last 8 years,
along with a number of enhancements to make it more powerful and
more user-friendly. With the Hourly Data System some clients have
achieved as much as 35%
improvements in production in the first month, we expect even
greater success with the new HDS.
is a visual system that can easily be configured to a number of
parameters including shifts, crews, standard work week, time measurement
intervals, trigger levels, brands, stop-codes, etc. Like the Hourly
Data System, it overcomes many of the weaknesses of traditional
shop-floor data collection systems. The HDS
provides real-time information, comparing performance at regular
time intervals with historic performance for each production module.
Each hour is a new hour, so Operators are motivated to reach short-term
performance targets throughout their shift (in most cases hourly).
The graphic display makes it easy to recognize trends in production
so proactive measures can be taken before
a major problem occurs. Management can monitor production and gain
a better understanding of what factors are limiting, or facilitating,
The new HDS
is capable of retrieving production data directly from the packers
(or case packers) and will interface with the makers to download
fault codes for below-trigger performance intervals. All charts
and graphs are generated automatically, with enhanced flexibility
allowing analysis by cell, machine type, crew, etc. The second phase
of development will integrate the HDS
with SAP, allowing you to download throughput and reject data to
SAP and enabling the integration of maintenance tasks with the SAP
©2004 HMC, Inc. All rights reserved.