Measuring the Savings from Metrics

Enterprise Resource Planning vendor SAP Americas, in Newtown Square, Pa., did a survey of its manufacturing customers and found direct savings related to viewing metrics as different aspects of plant operations.

Following are the findings on tracking a metric and using the metric to optimize the plant. The survey results translated metric tracking into performance improvements.

Metric: capacity utilization
• Tracking personnel during work shifts based on qualification and availability led to 15 percent higher capacity utilization
• Allocating equipment and tools to operations based on production plan, and tracking their usage and status in real-time led to 15 percent higher capacity utilization
• Real-time monitoring and tracking of processes, orders, operations and exceptions led to 10 percent high capacity utilization.

Metric: overall equipment effectiveness (OEE)
• Allocating equipment and tools to operations based on production plan and tracking their usage and status in real-time led to 40 percent higher OEE
• Enabling real-time monitoring and tracking of data processes, orders, operations and exemptions led to 15 percent higher OEE.

Metric: on-time delivery
• Consumer products companies that ensured tracking and directing of personnel during work shifts based on qualification and availability led to 10 percent improved on-time delivery
• Consumer products companies that enabled real-time monitoring of data about processes, orders, operations and exceptions led to 10 percent improved on-time delivery.

Related Feature - Metrics are spreading to the Manufacturing Dashboard
To read the feature article relating to this story, go to www.automationworld.com/feature-7258.

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