PERFORMANCE INDEX (PI) HOW TO ANALYZE AND IMPROVE PACKAGING LINE PERFORMANCE

摘要

Most companies that are involved with automated packaging systems, monitor their output in either "cases per day" or "hectoliters per shift" or some other suitable output figure. "Case Counts" is a good bottom line measure considering the typical requirements of upper management. If the case count drops, it's time for upper management to ensure that appropriate action is taken to correct matters. All too often though, they send messages to middle management to "Get More Cases Out Of The Line Any Way You Can" ! This message is heard loud and clear through the ranks, through middle management, supervisors, operators and the maintenance team. Everyone's world revolves around the case counts. The problem with this type of direction is that it is often accompanied by little or no other information about how to analyze the packaging line and where to begin looking for the fault. Inevitably different parties start chopping at each and every visually apparent symptom. If by chance, the real problem is not stumbled upon, then this is typically followed by a more structured Downtime Analysis study and closely monitoring machine efficiencies. Downtime Analysis is undoubtedly effective but has its limitations as we will see later on . There just has to be a smarter system and one which is easy to apply and does not require additional time to use. This is why the "Performance Index" or "PI" has been developed. The philosophy behind "PI" is to help the packaging manager break down the lower case counts into general problem areas, then further into real individual causes and potential solutions. These can then be formed into an action plan, which when properly executed, will alter the case count in a positive manner. Coupled with PI are newer, more advanced analysis techniques that can be used together with Downtime Analysis, to help find the real causes of the problem areas and are very useful in line utilization improvement programs. It is, however, essential that PI be generally understood at the highest possible levels of management in order to affect lower case counts in a positive manner.