LPAc Tour

In this tour of LPAc, you will find the following topics are covered:

Summary of OEE as implemented through LPAc
Additional key Metrics implemented
LPAc Benefits
Details on LPAc Architecture and modules

Summary of OEE as implemented through LPAc

LPAc is an automated, state-of-the-art data acquisition system through which the Overall Equipment Effectiveness (OEE) of a production line will be computed. It enables continuous, real-time tracking of all production line events and relays the status of all operating equipment. It provides plant and management personnel with complete historical data and invaluable metrics to empower them as they reduce unplanned downtime and seek line efficiency improvement. It provides quality tracking, loss reduction and productivity assessment.

This type of efficiency monitoring system starts with the collection of all relevant data from individual machine controllers (PLCs) and then produces performance metrics including the OEE. The key components of OEE are Equipment Availability, Yield (Quality) and Production Rate – These are evaluated through the following key monitoring processes:

Equipment Availability tracking
Shrinkage tracking
Production Rate (performance) tracking.
Throughput tracking
Production Line Efficiency
Asset Utilization

LPAc is built up from several modules that instantly collect and compile complex and instantaneous production data from the most reliable sources, the PLCs. All LPAc calculations and KPIs are based on appropriate industry standards. Given that LPAc is web-based, this represents a leading-edge application and gives the fullest flexibility in providing actionable information wherever users need it, be they on the shop floor or in the executive suite.

LPAc is easily configurable in multiple languages and is applicable in a wide variety of packaging industries such as beverage, food, pharmaceutical and other consumer packaged goods.

LPAc can be applied to a single machine, to a single production line, to one factory or to a series of factories. This gives great flexibility in how LPAc can be implemented in your company. The Letico industrial automation experts can work with your team to design and execute the most appropriate initial implementation and ensure a successful commissioning. They can then help your management and operations people adapt to the new system and learn how to apply OEE effectively to maximize your production output and economics.

LPAc Benefits

An effective, robust and proven efficiency monitoring system such as LPAc provides the essential information that operations personnel need for hourly and daily decision-making and in priority setting. LPAc metrics and key running parameters point users towards the most relevant issues that are negatively impacting the line's output.

Some of the benefits seen at the factory floor level are:

Production Yield improvement
Quick R.O.I. on automation investments
Substantial reduction of unplanned downtime
Elimination of costly and unreliable manual status reports
Quality gains
Less overtime per employee
Improvement of working methods

With LPAc, senior management can more effectively supervise and manage a number of production facilities. Standardization of working methods and the promotion of best practices can be based on precise real-time and historical data. Monitoring and reporting the equipment performance and all plants' outputs enables managers to make strategic decisions, to effectively respond to customers' demands, to gauge the impact of different options and to better plan investments.

Some of the benefits seen at the executive floor level are:

Rapid overview of all plants' outputs
Better decision-making
Improvement of production flexibility
Rapid discovery of major bottlenecks and opportunities for increased throughput
Optimization of capital expenditures
Increased profitability

Details on LPAc Architecture and modules

In summary the LPAc system retrieves production raw data from any network-connectable PLC anywhere within the factory. The PCL for each piece of operating equipment collects downtime events, production and rejects counts information, or both, and reports that information to a Data Concentrator PLC. All equipment PLCs are programmed in the same standard manner, thus providing very efficient system setup.

This shop-floor data sensing and collection system then provides the basis for the whole LPAc information system illustrated simply in the following chart:

With accurate, real-time, detailed data on factory operations in the data warehouse, the LPAc system can provide to any operating or management level the information in the format they require for rapid and informed decision-making. Since LPAc is web-based, anyone with a web browser and secure access can receive the information they need at any time and in any place, even on a mobile device. It is even possible to have WiFi-enabled large portable display units on the factory floor to give the information the operators need for split-second remedial action.

Contact Letico for specific advice on how your LPAc system can be implemented.

Industrial Automation provides the ability to measure performance and Line Monitoring software can then support the production staff as they work on improving performance. LPAc, the Letico Line Management System, is a best-of-breed way of applying this approach.

Contact Letico for more information on how LPAc and OEE can be implemented in your factory. The references below give more information on OEE (Overall Equipment Effectiveness) for those wishing to explore the concepts more.