Functional Documentation

FMS
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FMS Proposal
System to monitor and analyze the production process using one branch of software, hardware and peopleware to collect data from the plant floor and improve productivity in real time. This system allows performance indicators statistics analysis in real time related to quantities produced, downtimes and machines losses:
Quality; Efficiency; Utilization; Productivity; Non Planed Stops; Planed Stops.

Implementation methodology considering people behavior as the main part of productive improvement process.
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FMS PMME Productivity Improvement Process PLANNING MONITORING MEASURE EVALUATION

DATA COLLECT

STANDARD DEFINITIONS DEFINE THE GOALS

INDICATOR: - PERFORMANCE - FTT - AVALIABILITY - OEE

ANALIZE THE ACHIEVEMENT

LINES STATUS FOLLOWING THE RHYTHM VARIATION STRATIFY THE CAUSE OF STOPS AND VARIATION TENDENCY ANALIZE

IMPROVEMENT ACTION

IMPROVEMENT ACTION

IMPROVEMENT ACTION

IMPROVEMENT ACTION

Behavior Change - Training

Motivation to productivity improvement;

Skills to productivity improvement using solving problems tools

Using the information;

Brainstorms;
Better Priorizations; Quick Actions;

Action Groups.
.
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Behavior - Action Taken Process

Survey Presentation Analysis Implementation Conclusion

Approved Approved Waiting Analysis Analysing Not Approved Not Approved

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Evaluation

Effective

Discarded

FMS Closed-Loop Production Management

FMS Key Performance Indicator (KPI) Concept

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS UNPLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS TIME LOST BY REWORKING PIECES TIME LOST BY PIECES SCRAPPED

NET PRODUCTIVE TIME

TPM indicators (Total Productive Maintenance)

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS UNPLANNED STOPS

FTT = NET PRODUCTIVE TIME GROSS PRODUCTIVE TIME

OPERATIONAL TIME TEMPO OPERACIONAL

RUNNING TIME

PERFORMANCE = GROSS PRODUCTIVE TIME RUNNING TIME

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS TIME LOST BY REWORKING PIECES TIME LOST BY PIECES SCRAPPED

NET PRODUCTIVE TIME

AVAILABILITY = RUNNING TIME AVAILABLE TIME

Overall Equipment Effectiveness OEE = FTT x Performance x Availability Asset Effectiveness AE = OEE x TIME AVAILABLE

TOTAL TIME
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Key Performance Indicators

INDICATORS
FTT ( First Time True) PERFORMANCE

FORMULAS
NET PRODUCTIVE TIME / (GROSS PRODUCTIVE TIME) GROSS PRODUCTIVE TIME / RUNNING TIME RUNNING TIME / TIME AVAILABLE FTT * Performance * Availability

T P M

AVAILABILITY OEE (Overall Equipment Effectiveness) AE (Asset Effectiveness) QUALITY

OEE * Available Time/Total Time (TIME LOST BY SCRAPPING + TIME LOST BY REWORKING) (GROSS PRODUCTIVE TIME)

EFFICIENCY

NET PRODUCTIVE TIME / RUNNING TIME

RUNNING TIME / OPERATIONAL TIME NET PRODUCTIVE TIME / OPERATIONAL TIME UNPLANNED STOPS / OPERATIONAL TIME 9

F M S

UTILIZATION PRODUCTIVITY UNPLANNED STOPS

PLANNED STOPS

PLANNED STOPS / AVAILABLE TIME

FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME

OPERATIONAL TIME

PLANNED STOPS

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

QUALITY =

(TIME LOST BY SCRAPPING + TIME LOST BY REWORKING)

GROSS PRODUCTIVE TIME

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FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

EFFICIENCY =

NET PRODUCTIVE TIME RUNNING TIME

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FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

USAGE =

RUNNING TIME OPERATIONAL TIME

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FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

PRODUCTIVITY =

NET PRODUCTIVE TIME OPERATIONAL TIME

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FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

UNPLANNED STOPS =

UNPLANNED STOPS OPERATIONAL TIME

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FMS Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

PLANNED STOPS =

PLANNED STOPS AVAILABLE TIME

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TPM Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

FTT =

NET PRODUCTIVE TIME GROSS PRODUCTIVE TIME

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TPM Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

PERFORMANCE =

GROSS PRODUCTIVE TIME

RUNNING TIME
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TPM Performance Indicator

TOTAL TIME
24 HOURS X 365 DAYS

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

UNPLANNED STOPS

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS

NET PRODUCTIVE TIME

TIME LOST BY REWORKING PIECES

TIME LOST BY PIECES SCRAPPED

AVAILABILITY =

RUNNING TIME AVAILABLE TIME

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TPM Performance Indicator

TOTAL TIME
24 HOURS X 365 DAY S

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS UNPLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS TIME LOST BY REWORKING PIECES TIME LOST BY PIECES SCRAPPED

NET PRODUCTIVE TIME

OEE = FTT X PERFORMANCE X AVAILABILITY OEE =

NET PRODUCTIVE TIME GROSS PRODUCTIVE TIME x GROSS PRODUCTIVE TIME x RUNNING TIME RUNNING TIME AVAILABLE TIME

OEE =

NET PRODUCTIVE TIME

AVAILABLE TIME
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TPM Performance Indicator

TOTAL TIME
24 HOURS X 365 DAY S

AVAILABLE TIME

NON WORKING TIME PLANNED STOPS UNPLANNED STOPS

OPERATIONAL TIME

RUNNING TIME

GROSS PRODUCTIVE TIME

TIME LOST BY SPEED LOSS TIME LOST BY REWORKING PIECES TIME LOST BY PIECES SCRAPPED

NET PRODUCTIVE TIME

AE = OEE x AE =

AVAILABLE TIME

TOTAL TIME
NET PRODUCTIVE TIME X AVAILABLE TIME

AVAILABLE TIME
AE =

TOTAL TIME
NET PRODUCTIVE TIME

TOTAL TIME
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Reports Consolidation Hierarchy

Plant
Plant

Areas

Area A

Area B

Sectors

Sector A

Sector B

Sector C

Sector D

Groups

Group A

Group B

Group C

Group D

Group E

Group F .

Resources

R1

R2

R3

R4

R5

R6

R7

R8

R9

R10

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Consolidation Hierarchy
Visualization by Management Level
Managers .

Supervisors

Resources

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