ABB process audit scheme helps efficiency soar for UK manufacturers

Citation

(2005), "ABB process audit scheme helps efficiency soar for UK manufacturers", Assembly Automation, Vol. 25 No. 1. https://doi.org/10.1108/aa.2005.03325aab.003

ABB process audit scheme helps efficiency soar for UK manufacturers

ABB process audit scheme helps efficiency soar for UK manufacturers

Keywords: Planning, Optimization, Product management

An innovative new manufacturing audit scheme from the leader in automation technologies ABB is helping UK-based industry increase production efficiency two or even three-fold through simple, cost effective steps.

The scheme closely aligns with the development of overall equipment effectiveness (OEE), which the motor industry for one uses as a method of assessing its first-tier suppliers, as this accurately reflects production efficiency.

OEE is the measurement of overall output efficiency of a given process in relation to availability, performance, and quality (right first time). By calculating OEE, losses in productivity and where they occur can be accurately pinpointed while also providing Information on where improvement efforts should be based.

A world-class OEE performance is considered as a measurement over 80 per cent, however many manufacturers languish at 50 per cent or lower, unaware that a few simple changes in operations, coupled with modest investment, can reduce cycle times, improve productivity, and lower unit cost.

In accord with this service requirement, ABB has rolled out its process audit scheme. Forming part of ABB's Process & Application Consulting Services (PACS) a process audit can speedily gauge OEE, allowing the ABB team to then work with the customer to improve it (Plate 1).

ABB's PACS manager John Flynn comments: “The automotive industry is just one industry that expects its manufacturing suppliers to address efficiency as a matter of urgency, therefore a company that can quantify its efficiency and demonstrate the pathways in place to raise that efficiency further, has a clear lead over its competitors. It is not just geared at the automotive industry however. Our audit can impact and improve any engineering or manufacturing function.”

The ABB process audit comprises a half-day audit of a customer's selected robot cell, followed up by an in-depth report, an estimate of “observed OEE”, and recommended ways of improving production to achieve “target OEE”. This can be followed up with a full manufacturing assessment or relevant cell upgrade.

Plate 1 A process audit can speedily gauge overall equipment effectiveness (OEE), allowing the ABB team to then work with the customer to improve it

The audit includes recording a digital video of the robot cycle and close examination of the logistics of parts handling. This could include checks in areas such as cell configuration; conformity of wiring safety circuits; robot program logic check; condition of cell including maintenance/house keeping standards; check of maintenance records to ascertain major maintenance problems; as well as feedback from operatives/team leader/supervisors etc.

Typical recommendations, which could improve OEE by 30 per cent, might include: fitment of powered work piece positioners into the welding cell; introduction of “Single Minute Exchange of Dies” (SMED) practices; fitment of production monitoring software; improved house-keeping around robot cell; investment in stock of critical spare parts; upgrade of guarding system in conjunction with powered work piece positioners; and review of training records and requirements for the operators and maintenance personnel. Recommendations can obviously be extremely wide-ranging and varied, depending on the specific application.

The follow up report not only identifies areas of improvement, but also provides accurate estimations of current production losses through inefficiency and “pay back time” for proposed improvements.

Besides automotive suppliers, ABB has audited companies in a wide range of disciplines including oil and gas, white goods and the food industry.

BEL Valves of Newcastle, a leading manufacturer of bespoke high-pressure valves for the oil and gas and petroleum industries, is one such company that has undergone an ABB process audit procedure. Operations Manager Paul Smith comments: “Though many of our products are custom-built and often supplied singly or in low volumes, manufacturing efficiency is still very important to us and our robot cell is a key part of operations. The ABB process audit provided an objective, informed and bang-up-to-date examination of our cell procedures and identified several likely areas for development”.

He adds: “One proposal of real interest to us is the possible replacement of our ageing robot with a new model. The old robot could then be refurbished and subsequently operated as a standby, allowing production to be safeguarded around- the-clock. Not all of ABB's recommendations require investment however – some basic changes in cell layout, housekeeping and logistics, are set to bring significant savings and increase our OEE performance figure on their own”.

Summing up, John Flynn comments: “Take-up for our service is increasing as customers realise the massive impact the audit can have on their business, with payback on productivity enhancements achieved in some cases in a matter of a few weeks. To date this year over 10 companies have had their OEE figure significantly increased through the ABB process audit scheme, making them more competitive, more cost effective and more appealing to their customers.”

For further information, please contact: David Marshall, ABB Manufacturing Automation, Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ. Tel: +44 (0) 1908 350300; Fax: +44 (0) 1908 350301; E-mail: david.marshall@gb.abb.com