Maybe that is why the Holistic
Data System (HDS) from HMC
is so successful. The New HDS
is a visual system which allows Operators and Managers to see how
production is evolving each hour. And while the system is designed
to interface directly with the PLC, it still requires Operators
to input a reason code for below trigger-level performance.
Having the HDS
screen visible is key. It enables anyone to walk through the factory
floor and within a few minutes know exactly what is going on and
where to focus attention. For example, you can quickly identify
a machine that is behind target based on the level of the average
line and the bars that represent hourly production.
This allows you to not only anticipate
output or volume issues, the evolution of production hour by hour
enables you to quickly determine if the problem has been resolved
or if it requires further attention - so you can congratulate the
team on the successful rectification, or quickly get to work understanding
what might be causing poor performance.
While frequent walks through the factory are important, the New
is network-based and works in real-time, which means that Managers
can view performance from their offices as well. Armed with this
information, Managers can make targeted visits to modules to recognize
strong performance or intelligent questions and offer appropriate
help or additional resources to solve problems. This also lets operators
know they are being watched AND that their feedback is being looked
at and acted on. If you are tight on a brand for a shipment, you
can monitor production hour by hour.
Entering a reason code is an important opportunity
to elicit feedback from the Operators and involve them in the process.
Not only does it force them to think about what may be causing the
problem, it may foster understanding and lead to corrective - or
preventative - actions.
We have seen plants try to work only with the PLC
output, and the result is data overload. Not only is the quantity
of information overwhelming, it can be very misleading. For example:
an Operator has a problem, opens a guard, clears the problem and
closes it; and then he opens the guard again (if he is not satisfied
with his 'fix'), and the problem shown on the PLC might just be
'guard open'. This information does not help us understand what
caused the stop, and if we are relying solely on the PLC we have
missed an opportunity to get valuable information from the Operator.
The new HDS
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.