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Performance and Uptime Analysis for Production Lines at ConAgra

Performance and Uptime Analysis for Production Lines at ConAgra. ConAgra Team: Bob Narcum Mike Tracy Principal Investigators: Erhan Kutanoglu, Ph.D. Terry R. Collins, Ph.D., P.E. Earnest W. Fant,Ph.D.,P.E. Research Assistant: Fernando Tovia. About ConAgra.

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Performance and Uptime Analysis for Production Lines at ConAgra

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  1. Performance and Uptime Analysis for Production Lines at ConAgra ConAgra Team: Bob Narcum Mike Tracy Principal Investigators: Erhan Kutanoglu, Ph.D. Terry R. Collins, Ph.D., P.E. Earnest W. Fant,Ph.D.,P.E. Research Assistant: Fernando Tovia

  2. About ConAgra • Total sales: $27 billion • In North America • No. 1 foodservice manufacturer • No. 2 retail food (grocery) supplier • Selected Brands: Healthy Choice, Butterball, Banquet, Hunt's, Orville Redenbacher's, Reddi-wip, Slim Jim and Armour. • 80,000 employees located around the world • ConAgra Frozen Foods is one of the operating companies

  3. Project Objectives • Performance Analysis and Benchmarking • How well does the system work as compared • To best case scenarios? • To worst case scenarios? • What is the maximum level of performance that can be achieved? • Develop a performance model that allows the evaluation of different alternatives on a daily basis in order to keep the process closest to the best case scenario

  4. Approach Choose measure of performance. Model interactions. Verify and validate model. Define objectives Verify Constraints Identify alternatives Operations Analysis Compare alternatives. Choose policies. Ask, “what if questions” Systems Design Compare controls. Optimize controls. Sensitivity analysis. Implement policies. Train users. Fine tune system. Implementation Validate model predictions. Identify other controls. Evaluate system performance. Look for oversights. Identify future opportunities. Evaluation

  5. Phase I • Select a production line that will be used as a pilot study • Use current data and information that is being collected daily • Analyze and classify data in order to identify the key parameters that have a major effect in the up time % and throughput

  6. Phase II • Analyze the basic performance of the production line under the following scenarios: • Best-case performance • Actual or practical performance • Worst-case performance

  7. Phase III • Identify the areas of potential improvement • Root causes of problems • Bottleneck analysis • Analysis of factors affecting performance • Sensitivity analysis • Optimization

  8. Phase IV and V • System design and Tool Development • Provide a tool that will allow the evaluation of different alternatives on a daily basis in order to keep the process as close as possible to the best performance • Implementation and Evaluation • Present implementation suggestions • Evaluate the system performance after suggestions are implemented • Replicate the implementation suggestions to all the production lines

  9. First findings • Potential Improvements and opportunities: • Downtime/Uptime analysis • Reduce or eliminate rework • Production scheduling • Shift scheduling and staffing • Line speed versus quality/quantity

  10. What has been done? • Data collection and analysis • Uptime/downtime analysis • Net throughput • … • Short-term implementation suggestions • Special Shift Scheduling • Overlapping activities • Experiment with speed reduction

  11. What’s next? • More operations analysis • Finding the relationship between speed and the other performance measures • Downtime • Rework • Both affect the net throughput

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