To help your company achieve
success, the new HDS
has flexibility designed-in. This helps ensure that the HDS
will provide you with the information you need to better understand
the process, to discern the capabilities of operators and mechanics,
and to identify the highest-leverage improvement opportunities.
Special Reason Codes
When performance in any time interval is below the trigger level,
the system asks for a reason code. In most cases these will be reason
codes for downtime, however you may might want to design specific
codes to record other activities as well. For example, you might
want to record all adjustments, or adjustments of a specific type.
Or you may want to collect data on quality deviations or even on
is designed to adapt to these needs and adding new codes is quick
and easy. Simply establish new codes for the data you want, and
train operators in how to use them appropriately. It is important
to remember that reason codes can be entered at any
time, not just when required because of below trigger-level performance.
Operators can enter reason codes as often as needed - each time
they decide to make a certain adjustment, for example. It is then
possible to analyze the data as usual and gain more detailed information.
With this data on adjustments, you will be able to identify which
shifts do the most adjustments, how they effect machine performance
and you could even look at the PLC reason codes for those hours
when an adjustments are made to find more information about the
machine status before and after the change.
main screen includes a 'Stops Ranking'
which displays the top problems for
a defined period. This feature can be set to rank by duration
(total time recoded as lost for that reason code) or by frequency
(number of times the reason code appeared) in a specified time period
- or both, depending on your needs.
In general, Managers focus on
the problems with the longest duration because this converts directly
to lost production minutes. However, small problems that occur frequently
can drain the energy and enthusiasm of your Operators. You can read
more about the 'Stops Ranking' feature
One of the exciting new features of the HDS
is a multi-parameter capability
which allows you to measure performance in more than one way. Target
and trigger levels can be set based on throughput
- for a high-volume production module, for example - or based on
reject or quality levels.
This additional flexibility allows you to monitor and analyze performance
based on the parameters that are most critical for each machine.
The new HDS
will be available at the end of April, 2004. Stay tuned for more
information on this commercial grade system, or contact
HMC for further details or to see a demo
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.
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,
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