Seeking Perfect Flow PDF
Seeking Perfect Flow PDF
Seeking Perfect Flow PDF
This article discusses how production lines are frequently balanced and controlled and
how we believe this can be improved to provide as much as a 10% OEE improvement on
your line.
The objective of every line balance and control philosophy is to maximise the line OEE
through minimising the effect of minor stops on the critical machine (the equipment that
determines the throughput of the line e.g. Filler)
If you have any comments or would like to discuss line control philosophy please call a
member of our team right away on +44 1564 793 211 as we are always delighted to help.
Block production lines operate with most machines running at the same speed. Typically
block lines run with very little conveyor space between the machines (often single track).
Therefore a stop on any of the blocked machines quickly or instantly causes a direct loss
of OEE / performance for the line.
Machines are typically controlled through linking the PLC controls to change speeds/stop
automatically for the entire line.
Accumulation production lines operate with individual machines linked with large
amounts of conveyor space and generally take up a lot of factory space. Typically the
machines in an accumulation line have the capability of running at variable speeds, and
will normally have one machine (or one block of machines) which runs the slowest; we call
this the bottleneck or critical machine.
The OEE / Performance of this line is determined by the amount of time that we are able
to keep the critical machine running at its rated speed.
Assuming good line balance and control; the accumulation minimises the impact of minor
stops of all machines on the critical machine
Machines are typically controlled by conveyor-based sensors with little direct interaction
between the machines.
Line control or line philosophy is the way in which machines are stopped/started in
response to changing conditions on the line. E.g. Stopping in build back when a machine
downstream stops, stopping in lack when a machine upstream stops.
2. Set the machines immediately before and after the critical machine to run (typically)
10% faster than the critical machine.
3. Set every other machine to run10% faster than the one previous one.
4. Machines use sensors on infeed and out feed to identify lack or build back events.
Disadvantages:
1. The only machine that will run at a consistent speed is your bottleneck machine,
every other machine will be constantly stopping in either lack or build back
2. When machines are constantly starting and stopping, or even changing speed, often
you greatly increase inertia changes. Changes of inertia often cause; an increase in
minor stop frequency, reduced machine operating window, increased wear on
mechanical parts, increased breakdown rate and therefore maintenance costs and
potentially an increase in the number of quality issues.
The above is a guideline to how lines can be set up with V-Curve theory. It is worth
recognizing that every line is unique and that modifications to this theory may be necessary
for optimum performance.
We believe that by optimising your line balance and control we can add up to 10% OEE to
your production line.
In practice this old way of controlling a production line gets you quite close to achieving the
objective of line balance. However it is a long way from Perfect flow, and with technology
taking huge steps, communication between PLCs is much easier, and therefore it is
possible to control lines at a whole new level of precision.
The example utilised here provides a reference that can be easily imagined and is very
close to achieving perfect flow.
Imagine stacking hour glasses on top of each other, with the hole in the 2nd one down
being smallest (Critical Machine) and the holes (machines) increasing in size (speed) as
you move away from this one.
-The glass balls (conveyors) before the critical machine are full before and after
empty.
-The flow through the whole system is determined by the smallest hole (critical
machine)
-The single stream of sand (containers) through the holes (machines) after the
smallest hole (critical machine) leaves lots of space in the event of a stoppage
lower down - Stops of flow can occur on holes (machines) other than the
smallest hole (critical machine) without affecting the overall throughput.
B - In a stoppage condition:
-The glass balls (conveyors) fill all the way up
-The flow through the smallest hole (critical machine) keeps consistent (design
speed) until there is no more space below
The 5 levels of control are all steps that you can take (perhaps with the help of someone
with some PLC skills) to modify your existing line control with a minimum of investment.
Now that you have logged onto our website E-Coaching letter we will email you a weekly
newsletter free of charge in which we will take you through the five levels of control and how
you can apply them to your lines.
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OptimumFX Ltd.
10 Ardent Court, William James Way, Henley-in-Arden, B95 5GF United Kingdom