Make an IMPACT with OEE!

1. Make an IMPACT with OEE! Productivity Improvements Come as Standard Section 1: What is OEE Section 2: OEE IMPACT Software + Connect By: Gemba Solutions Ltd - Designer & Manufacturer Control Dynamics, Inc – Distributor & Integration Partner Bringing to you OEE LEAN IMPACT Software Products

2. Introduction • Using OEE Impact Software will revolutionize the way in which you collect and analyze your manufacturing shop-floor data. its feature-rich functionality and easy to use interface enabling you to save countless man-hours over your current methods of collecting and analyzing machine performance data and bottlenecks. • OEE IMPACT has been specifically designed around the industry accepted and proven OEE Calculation standard and includes all the tools you need to measure and Impact your productivity and capacity. • However, OEE Impact goes a step further in providing a host of additional features compared to a standard OEE based solution. From the experience we have gained over many years, we have logically extended OEE IMPACT to incorporate valuable capabilities to allow the collection and analysis of virtually any efficiency data, such as: Machine / Line Set-up Time; Product Analysis; Scrap / Rejects; Re-work; Maintenance Times; etc.. • It doesn’t stop there. OEE IMPACT is fully scalable and can be expanded with a number of add-on modules, including the automatic collection of data in real-time from your shop-floor assets. As a part of the LEAN Impact Suite of products OEE IMPACT will give you confidence that it will never be outgrown, making OEE IMPACT an invaluable tool now and into the future with which to manage your business. • We guarantee that OEE IMPACT will become a key component in your productivity toolbox, enabling you to get to grips with an impact: • Machine cycle time • Machine availability • Downtime • Utilisation • Throughput • Shop Floor losses • Maintenance performance • Product performance • Mean time between failures • Bottle neck identification • Production and shift performance • Improve capacity planning • Wastage / Scrap / Rejects Analysis • Plus much, much more…….. • Don’t just take our word for it. Ask for a ‘fully featured’ free trial • of OEE IMPACT product today and see what your OEE figures really are.

3. Key Performance Indicators • Machine cycle times • Machine availability • Downtime • Utilization • Throughput • Shop-floor losses • Maintenance performance • Product performance • Meantime between failures • Bottleneck identification • Production and shift performance • Target capacity planning • Waste / Scrap / Rejects • Plus much, much more…….. Don’t take our word for it - ask for the ‘fully-featured’ demo of OEE IMPACT today and see what your OEE figures really are!

4. What is OEE If you don’t measure how can you hope to manage it? No matter what type of process or manufacturing operation you are involved in and regardless of your company size you are likely to be under constant pressure to improve performance, improve quality and increase equipment availability. Targeting any one of these three key areas for improvement, availability, performance or quality, may seem a major task and addressing all three together may seem a daunting task. However, if these areas can be addressed simultaneously, then significant improvements can be made throughout the production process. Production Output can be increased, Product Variations can be expanded and Production Cost Reductions can be achieved. A good starting-point in attempting to achieve this is to identify and focus on simple but effective areas of the efficiency tree, areas such as asset (machine) performance which is always a hot topic. This is where OEE Analysis (Overall Equipment Effectiveness) can really help to make a difference to your productivity decision-making on a day-to-day basis. OEE is a simple but clever calculation which focuses on individual items of process or manufacturing equipment at a finite level and allows their ‘effectiveness’ to be measured individually or in groups (i.e. with other equipment items). The OEE calculation is based on the ratio of the three key production parameters, availability, performance, and quality with time (e.g. planned shift time/s) being used as the baseline measurement. • The Calculation: • OEE% = Availability % x Performance% x Quality% • where: • Availability % = actual running time / planned cell production time • Performance% = pieces produced / the theoretical cell production rate • Quality % = good pieces / total pieces made

5. What is OEE OEE = Availability (B/A) X Performance (D/C) X Quality (F/E) Planned Shift APlanned Machine Production Time Idle Time BActual Running Time Down Time C Theoretical Machine Production Rate D Actual Production Rate Speed Loss EPieces Produced FGood Parts Scrap / Rejects

6. Measuring OEE • Simple system (can be achieved with manual data collection and entry system) • Machine Status (Running or Stopped) • Product Count • Quality Rejects • Simple stoppage reasons (Critical, Moderate, Non-Critical) • Cost Effective way to produce and distribute reports to plant personnel • More advanced (usually achieved with automated data collection system) • Machine Status (Running or Stopped) • Product Count / Rates • Quality / Rejects • Asset Grouping • Event Line Viewers / Dashboards • Job Planning / Queuing / Dispatch • Advanced Security • Multiple Downtime Reasons categories • HR / Machine Operator Tracking • Why not consider a “mix & match” method • Manual Data entry and Automated Collection! • Start Small but THINK BIG Scalability

7. Start small but Think Big = scalability • Manual Data Collection • Collect the data through paperwork entry forms filled in by operators • Replace Excel or Access Software Solutions • Analyse with OEE IMPACT • Manual and/or Automated Data collection • Install OEE IMPACT Connect and collect data automatically from assets. • Analyse with OEE IMPACT in real time and Historically Here is an example of how it would works:

8. Configure OEE IMPACT (one time only) Keyboard Production Data from Forms into OEE IMPACT Reports at anytime and/or up-date historical records as needed. Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators. Shop floor operators fill in production data forms as required. How OEE IMPACT Works (manual data collection)

9. How OEE IMPACT Works (manual + Automated data collection) Configure OEE IMPACT (once only) OEE IMPACT Powerful automated reporting tool with over 200 standard reports allows easy analysis of OEE data and much more… Automated Data Collection into OEE IMPACT Server. Print out OEE IMPACT pre-configured production forms. And distribute to shop floor operators. Shop floor operators fill in production data forms as required. Input Data from Production data forms into OEE IMPACT Reports

10. Typical OEE IMPACT Connect OEE IMPACT Clients Manual Ethernet+ Wi-Fi / RS485 Open Data Interface Input Data to OEE IMPACT through CSV Interface from (ERP, SCADA, DCS, Excel, SQL etc..) OEE IMPACT DCT Third Party Interface Specific software data interfaces to SQL, OPC, SCADA, ERP, CMMS and many other interfaces to collect operational data required for OEE IMPACT data logging

11. OEE IMPACT Connect DCT • OEE IMPACT CONNECT D.C.T (Data Connection Terminal) • Price for features delivered leader in market place • Features • Ethernet (Wi-Fi) • Up to two serial ports (barcode reader HR Cards, RF ID etc..) • Outputs • Mains powered • Compact • Easy to configure • Internal I/O power supply (24v) • Expandable with data logging • Compact design • Can be used with LEAN IMPACT MES Systems • Hardware Connectivity • PLC’s • PC’s • OPC

12. Manual Data Entry Form Selecting the data entry screen Entering scheduled downtime OEE IMPACT will track production runs, not just machine performance Production information Downtime reasons

13. Production Performance Diagram of production losses Selecting the shift effectiveness Tab Final effective production time

14. Shift OEE OEE Summary Production Units Shift OEE performance

15. Reporting Tool • Over 200 pre-defined reports as standard • Total flexibility on reporting • Graphical charts • Text reports • Fast data retrieval • Export data to nearly any file or program type • Get reports that drop into Word or Excel • Send reports to printers, via emails and through other mediums. The following slides provide an overview of the power offered by OEE IMPACT’s comprehensive reporting tool. If you want to try OEE IMPACT for a limited time free of charge contact our sales team and ask for your trial copy - then you can see the true power of OEE IMPACT Reporting…

16. Report Generator Selection of report type Report Filter provides the facility to simply drill down into the information Selection of display options: trends, bar graphs, data grids, units of display. Group data by Machine, shift, product, operator Open and save commonly used reports Display reports in 3D

17. Downtime Summary Downtime Histogram: All charts can be user-configured

18. Downtime Components Downtime can be grouped into categories of your choice Machine 3 has a high Idle time Equipment failure accounts for most of the downtime. Could be time for a planned maintenance program!

19. Downtime Trend Use Zoom to see more detail Trend of downtime over time Auto Scaling Axis

20. Machine Failure Failures can be displayed as number of failures, duration, average duration, time between failures, MTBF, MTTR…. Identify failure-time per machine

21. Simple Reject Report Show rejects per machine by type. OEE IMPACT allows for as many reject types as you need.

22. OEE Components OEE IMPACT provides a vast array of tools for analysing OEE, this being a starting point The components of OEE

23. OEE for all Machines Most Effective Machine Machine 6 should be identified for a production improvement project

24. OEE Time Trend Quickly see trends and short-term problems

25. OEE Grid View A Unique view of OEE generated by OEE IMPACT Rapidly identify production hot spots A grouping of poor performance on a particular day

26. Production Performance This chart shows a clear trend of falling output Identify the relationship of good parts to bad. Drive a first-time-right campaign

27. Data Grid All charts will flip to display the raw data. This data can be simply cut into other application Sort the data on the TAB headings

28. Chart Editor With the Chart Editor tool you can configure and change the appearance of the report. ADD extra analysis points; trends, averages. Import external data

29. Report Summary • In this short presentation you have seen a fraction of what the OEE IMPACT reporting tool has to offer. • With over 200 report formats to choose from OEE IMPACT has the report you need, from simple text summary reports to complex multi-display 3D/2D charts on the same screen. • Identify major problems quickly and use OEE IMPACT’s report generator to drill down onto the major issues.

30. Real Time OEE • Enhanced Security • Real Time Data Capture • Production Schedules • Real Time User Configurable Graphics • Time Line Event Viewer • Operator Asset Dash Board • Data import from XML files • Third Party Interface • OEE Asset Grouping for lines , cells, areas, etc • Unlimited free network users  • OEE IMPACT Data Collection Terminals DCT • The Following slides show a sample of the many expanded functions and features you get in OEE IMPACT CONNECT

31. Real Time Graphics Page displays are configured in 30% of the time of SCADA systems Real Time Graphics Viewer from extended menu options in OEE IMPACT CONNECT Selectable Cell/Line production performance Figures including OEE

32. Line & Cell Production Cell Based OEE and Performance Monitoring Line Based Production Production trends showing in real time as changes in today's production allowing rapid responses

33. Performance Summary • Three OEE Outputs • Shift performance to date • Performance of all jobs to date • Current Job Ability to Manually Enter Downtimes and Events Real-time OEE and Production Displays. Red and Yellow levels of warnings Real Time Pareto Charts

34. Event Viewer • Review • Manual • Scheduled • Automatic • Events • Spot Bottle Necks • Cycle Times • Operator Actions With the correct security levels modify recorded events

35. Production Schedules Create Production Schedules for the day and allocate the Jobs to machines, cells and lines. Plan using Operations and Routes for you individual product standards

36. OEE IMPACT Product Modules Full HR Tracking Batch Recording ERP Interface OEE IMPACT Connect Product Tracking OPC Recipe Handling OEE IMPACT Enhanced OEE LEAN IMPACT Server (SQL) OEE IMPACT Server (MSDE) Trending + Others Gemba Solutions Software Product Range Additional LEAN IMPACT Products

37. Hardware & Software Requirements • OEE IMPACT minimum recommended PC requirements: • Software Recommended • Windows 2000 or XP (latest service packs) • Minimum Hardware • PIII 800 or equivalent • 500 Mbyte hard disk space free • 64 Mbyte RAM • 1024x768 32 bit graphics card and monitor (preferred) • Network card (for multi-user configuration) Please check with our technical sales team for up to date requirements.

38. Summary • Price starts from only $2,995.00 • Full product demonstration available. • Manual and Real-time Solutions • Eliminate custom-built Access and Excel systems. • Unlimited network users (client Interface) included in the price as standard. • Over 200 standard reports included, together with a custom report builder. • Easy to install, configure and use. • Provides full standard OEE data entry and reporting as well as the ability to report OEE on labor, shifts, products and much more….. • Understand downtime, set-up, Scrap / Rejects, Idle time, Meantime Between Failure (MTBF) + more…. • Expandable and scalable to fully features LEAN IMPACT MES System. • Full web and telephone support service. • OEE IMPACT training courses available at CDI or on-site at your facility.

39. What People Say Here is what people are saying about OEE IMPACT: • “Not just another toolkit to see data” • “Configuration is easy and intuitive”. • “Data entry is a delight to use”. • “The reporting and analysis tool allows instant and outstandingly flexible reporting” • “Installation was simple and required no additional software”. • “The cost against the functions you get in OEE IMPACT are amazing”. • “Gemba Solutions have a real winner in OEE IMPACT”. • “Five network nodes ‘as standard’ allows exceptional flexibility”. • “Knowing OEE IMPACT is part of the CATS IMPACT MES Suite is a bonus”. • “OEE IMPACT is the most advanced OEE Management Software on the market”. • “Starting at $2995 this is real value for money, how does Gemba do it?” • “Well done Gemba Solutions for yet another really useful software product”. • “OEE IMPACT paid for itself in less than 2 months!”

40. Make a Difference Thank you for your time and for the opportunity ! Call our Sales team to be rushed your own fully featured OEE IMPACT Product today on the number below or request it from our web site at: Control Dynamics, Inc. 4246 Corporate Exchange Drive Hudsonville, MI 49426 (616) 896-2008 www.cdi-mi.com Garry Muma Mike Bridle Productivity Sales Engineer (616) 896-2032 (616) 896-2030