ARC reduces costs and empowers digital maintenance with API PRO

ARC, operators of Copenhill / Amager Bakke, Denmark’s largest waste incineration facility reduce costs and increase efficiency by transforming to digital maintenance worksflows with API PRO.

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Industry 4.0 – Beyond the Hype!

It is true that there is a lot of noise and hype around Industry 4.0, but this does not take away from the fact that it is real and inevitable If your organization is not prepared you will be left behind!

Consider for a moment this one statistic, a 10% increase in your OEE will increase profits by more than 20%!

For your organization to benefit from the advances being made in Industry 4.0 you need to have in place an Actionable Business Strategy. One very important key to remember is that Industry 4.0 is not just a technology shift, but a cultural shift for your employees and organization.

There are four essential aspects to designing an executable strategy that can be implemented in your organization.

  • Define the “Real Questions to Answer, such as production volume issues or quality issues and most importantly is the “Why” this is happening.
  • Understand your organizations current state and skill set’s. Do you have the staff and personnel with the capacity to implement and learn any new systems or technologies?
  • Identify and set both short and long-term goals. Your short-term successes will be the building blocks of the foundation for your long-term goals being met.
  • Understand the difference between “What” and “How”. The “What” is the strategy for achieving a goal while the “How” is the implementation that will achieve that goal.

Industry 4.0 is the convergence of many areas and disciplines within an organization including the teams working with Continuous Improvement, Lean, Production and Quality. It is important to have a partnership between these groups to avoid competing for resources. As an example, don’t choose between defect reduction or lean manufacturing, choose both and understand the impact one has on the other.

Let’s look at one area where these groups can come together in an organization, Condition based and Predictive Maintenance of Critical Assets

The data sent from production line or machine sensors deliver up to the minute information into a production monitoring solution such as AXXOS OEE. This collected data allows quality teams and production executives to have full control over and real-time visibility into their manufacturing operations. This visibility offers operational insights that help management identify opportunities to increase output, decrease costs and improve overall quality.

Now really expand the capabilities of production monitoring by integrating your OEE system with your CMMS system such as APIPRO. The integration between OEE and CMMS will enable you to combine condition data from critical equipment with operational data. Thereby you create the the platform for condition based as well as predictive maintenance and can eliminate unplanned downtime that results in lost productivity.

Three key reasons to consider an integrated AXXOS OEE- and APIPRO CMMS systems are;

  • Create the Platform for Continuous Improvement
  • Reduced Downtime with Predictive Maintenance.
  • Eliminate double entry of data.
  • Engaged Employees leading to increased productivity, fewer quality issues and lower employee turnover.
  • Most importantly all areas Production, Quality, Management will have the data to make better decisions in a shorter time frame.

API – AXXOS  brings over twenty years of experience of being a valued trusted partner to some of the largest manufacturers around the globe. The modular approach of each solution along with flexible deployment options means that any budget can be met. Aspects of being a world class solution that AXXOS OEE and API PRO provide include; supporting over 23 languages’, multi-plant, multi-time zone and multi-currencies.

Contact us today to learn how API – AXXOS can be your partner as you embrace Industry 4.0.

API PRO – A powerful solution for modern industry

API PRO is an Enterprise Asset Management system with a focus on flexibility, cost effectiveness and quality. API PRO is specialized and standardized in its functionality, and at the same time designed to integrate to additional business information systems.

Read more / download PDF here:

 

SMASh – API in new Chalmers project

Swedish companies want and need to get better at Smart Maintenance. At Chalmers a project is being launched to develop a benchmarking tool for Smart Maintenance within and between companies. SMASh is a collaboration between service providers and academic partners and API Maintenance is one of the participating companies.

Read more about the SMASh project here

Award – Outstanding EAM Supplier in China 2016

 

API China - Outstanding EAM Supplier 2016March 2017 – API China has been awarded as “Outstanding Supplier of Enterprise Asset Management 2016 in China” at the 6th Informatization and Industrialization Integrative Development Summit Forum in Beijing, China. The summit was sponsored by e-works global, and the theme was integration of internet in the manufacturing industry.

At the summit representatives from API Maintenance Systems analyzed EAM technologies and products with other best-in-class providers in the industry and shared experiences on cases and implementation strategies seen from a multi-perspective point of view.

Volvo Cars installs AXXOS OEE in new factory

AXXOS – member of the API Maintenance Systems Group – signed an agreement with Volvo Cars (Volvo) for the implementation of the production monitoring system, AXXOS OEE in Volvo’s new production facility located in Torslanda, Sweden. The agreement include networked production monitoring with about 400 production units and is currently the single largest order recorded for AXXOS.

Volvo selected AXXOS OEE after careful evaluation of seven competing systems and after a successful pilot installation within a focused area of the factory.

”Compared to the other systems we reviewed, AXXOS OEE offer a more complete solution for our requirements of built-in functionality that gives us “best practice”. We want to spend our time on improvements within our production, not to specify and develop IT solutions”, says Agron Basha, Business Project Leader, VOLVO CAR CORPORATION.

”AXXOS OEE will show us in black and white where we have problems and identify what they are, this in turn will help us set priorities. We will be able to collect data to facilitate decision making on which direction to work towards and where we get the most out of our investment”, continues Agron Basha.

The top modern Volvo factory in Torslanda manufactures the new XC90 model.The top modern factory in Torslanda manufactures the new XC90 model.

“The new XC90 is a market success and Volvo is using almost all available time to manufacture cars. AXXOS OEE will become an important tool in Volvo’s improvement strategy and will be able to identify, and map bottlenecks early”, says Johan Junvik, Key Account Manager, AXXOS Industrial Systems.

The agreement includes AXXOS OEE and AXXOS Analyze that makes it quick and easy to analyze collected information to identify improvement potentials within the organization. AXXOS OEE Mobile allow Volvo’s employees access to the production monitoring system directly on their mobile phones or tablets.

About AXXOS Industrial Systems
AXXOS has delivered systems for production monitoring, AXXOS OEE for almost 20 years. We help our customers streamline their production by packaging our experience in OEE-systems, LEAN-training and coaching in improvement. AXXOS is part of the API Group, supplying software for reliable and efficient production to 900 customers in 50 countries.

About AXXOS OEE
AXXOS OEE measures important KPI’s like the OEE value, set-up times, cycle times etc. AXXOS Visualize makes it easy to show the current production situation in real time. With the help of AXXOS Analyze it is quick and easy to analyze collected data to see the potential for improvement in operations.

Press images in Volvo Cars Newsroom

https://www.media.volvocars.com/image/low/155406/9_9/10?i=1

https://www.media.volvocars.com/image/low/203185/9_9/10?i=1

https://www.media.volvocars.com/image/low/203182/9_9/10?i=1

CMMS, EAM, OEE and TPM

CMMS, EAM, OEE and TPM

– An alphabet cocktail for manufacturing, maintenance and production

The goal of any manufacturer and production organization is fairly simple, get the most out of your equipment (assets), while producing quality goods. So how and where do each of the ingredients of the alphabet cocktail come into play?

api pro cmms oee eam tpm

CMMS (Computerized Maintenance Management System) is the absolute life blood of any top maintenance organization. You must be able to track who is doing what on each piece of equipment (asset), what was done, what parts were used, etc. You should be able to track your inventory, schedule your preventive maintenance as well as break fix and of course this should all be able to be completed on a mobile device. CMMS is the first key ingredient in the alphabet cocktail.

Top of the line CMMS systems have grown into much more incorporating EAM (Enterprise Asset Management). An EAM system takes things to the next level by tracking everything around the entire lifecycle of the asset. When was it purchased and from who, what sort of warranty is in place, tracking overhauls, depreciations as well of course all of the things a CMMS solution provides.

So now you are tracking everything you need to know about your equipment (asset) with a CMMS/EAM solution or are you? No the next key ingredient in the alphabet cocktail is OEE (Overall Equipment Effectiveness). It is one thing to fix your equipment when it breaks down or better yet try to prevent those breakdowns with an aggressive preventive maintenance program. Let’s remember one of the key goals of manufacturing and production is to get the most out of your equipment (assets).  This is where an OEE System comes into play.

The history of OEE can be traced back to metrics developed by Seiichi Nakajima in Japan during the 1960s to evaluate how effectively a manufacturing operation is utilized. OEE is based on availability, performance and quality rate.

Measurement of Overall Equipment Effectiveness (OEE), is becoming widely accepted as an overall measure of manufacturing effectiveness. However, when correctly applied, OEE is much more than a management benchmark. It is a powerful troubleshooting tool that identifies areas for improvement at the functional level.

It is important to remember that OEE is part of an overall improvement program and NOT just another KPI to measure. OEE is at its best when it is focused on one single asset or a synchronized line. Of course there are numerous studies of what a “World Class” OEE number is for a manufacturer or production operation. These “World Class” numbers should not be used as a benchmark. Remember OEE is about attaining improvements. A “World Class” continuous production operation might have an OEE number in the 90’s, but if you take your operation from the low 40’s up to the 60’s you have achieved a 50% improvement!

What can your maintenance program and your CMMS/EAM do to contribute to improving OEE’s three keys of availability, performance and quality?

That brings us to the fourth ingredient in our alphabet cocktail, TPM (Total Productive Maintenance). TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results (OEE). TPM is about bringing things full circle back to your CMMS and your PM program. The key though is, now it is not just seen as a maintenance department function. The focus is how you maintain your equipment throughout its life cycle. This requires the buy in from top management as well as front line production staff and operators. Production operators for example can and should be trained on simple preventive maintenance activities such as lubrications, how to note and track those activities within your CMMS.

People, culture and attitude
Remember when we talk about OEE and TPM we are not talking about a technical IT-project, sure technology will and does play a key role but more importantly we are talking about people, culture and attitude within your manufacturing operation. OEE and TPM projects need to have clearly focused primary financial business goals such as reduce scrap, reduce short stoppages and improve lead times. OEE and TPM are about continuous improvement in your manufacturing and production environment.

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Visual Planning

Precise planning and better utilization of resources

The Visual Planning function in API PRO provides a clear view of available personnel and displays a precise planning overview.

Online monitoring of work order progress

Optimize the utilization of the workforce and impro­ve the service le­vel with the Visual Plan­­ning function. The pro­cess is purely visual – with drag and drop you can control that work orders are delivered on time while utilizing your work­force optimally.

The efficient planning features make it easy to plan preventive and corrective work on groups or individuals in a user-friend­ly way.

To support group plan­ning a new way of grou­ping work force called “Capa­­city Group” is introduced.

  • When you have optimized the work load on the Capacity Group you can continue planning for persons, simply by “dropping” the persons on the work orders.
  • The “Week-plan” function provides a quick view of “when and where” the maintenance personnel will be working during the week. This view shows a combination of shift/working time, exceptions and capacity group for each person. visual planning overview
    Click on the image above to see a Visual Planning tutorial on YouTube.
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The Visual Planning function introduces more new features:

  • It is now possible to “take ownership” of work orders, while planning them. This prevents that more people, by mistake, plan the same work orders at the same time.
  • “Sign on and off” work orders and have the spent time calculated automatically.

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Visual Planning on YouTube
Watch the Visual Planning tutorial on YouTube.

API Maintenance Systems on YouTube: https://www.youtube.com/c/apipro