Positive return-on-invest (ROI) in three years

    Core-set of KPIs

    31/03/2015

    Benchmarking & KPIs: What does good performance look like?

    Glass International - April 2015

     

    In the day-to-day work of a glass plant, special expertise is necessary not only when production is interrupted but when new technologies are being implemented or plant performance is being pushed to the next level. Heye offers an advanced benchmark-set for technical assistance – an expertise for productivity and quality improvement in the glassmaker’s production.

     

    Many factors are required to achieve good glass. Processes are often complex and slight amendments might create severe problems. The Heye TAA-team consists of Glass People that were educated on the spot – in the glass production. They know that efficient production is not the result of a single person; it is always the result of a production team. Beginning from the batch composition through melting, glass conditioning, Hot End production and inspection quality control to the palletizing. The TAA-team has always the whole production in view. This is what Heye trains to its customers.

     

    MEASURABLE BENEFITS

    With its advanced benchmarking program and KPI-set Heye offers know-how transfer for efficient production and delivers a framework to track and measure the improvements. Measurable benefits are:

     

    • Rising plant productivity
    • Increasing product quality
    • Increasing job safety
    • Reduction of energy consumption

     

    RISING PLANT PRODUCTIVITY

    The goal of every glassmaker: Rising plant productivity! These are big words that require comprehensive analysis. The Heye experts examine the current production status by Pack to Time (PTT) and down time analysis.

    PTT is the total number of the glass containers sent to the warehouse (the number of good articles) divided by the total number of gobs cut during the machine hours available.

    Down time is chargeable when you lose tonnage and/or container due to breakdowns on technical facilities (Hot-end or Cold-end). All downtime reason’s leading to more than 1 minute of machine standstill should be reported.

     

    INCREASING PRODUCT QUALITY

    The KPI “critical defects in manufacturing” is the ratio of the number of critical defect reports per million good articles manufactured. Critical defects are defined as glass defects that could cause injury to a consumer or a filling line operative.

     

    JOB SAFETY: LOST TIME ACCIDENT RATE

    Lost time accident rate (LTAR) is the number of all lost time accidents (LTA) per number of FTEs (full-time equivalent employee, average number over the last 12 months). Lost time accident (LTA) occurs when the employee is absent for one day / shift or longer.

     

    ENERGY: GIGA JOULE PER PACKED TON

    This KPI calculates the energy consumption in relation to the packed tons. Influencing factors are e.g. the proportion of cullets in the batch, the efficiency of the furnace, the weight of the container and different details of the forming process.

     

    Having analysed these KPI Heye experts assist in optimizing output efficiency and product quality, whilst at the same time reducing overall costs.

     

    The application of the KPI performance analysis results in a positive return on investment (ROI) already in the third year, even if some investments in the technical infrastructure are necessary.

     

    NNPB OPPORTUNITIES

    A successful production with the NNPB-Process is not only the result of placing the equipment, a wide field of technology is necessary for the whole container glass production. It starts with the glass requirements and glass conditioning, including special equipment in the Hot End production area with the corresponding control technology. Also the mould design, the mould equipment, all the machine settings and the Hot End and the Cold End inspection equipment are important.

    From the long term experience of Heye in implementing the NNPB-Process, one of the major factors beside of the equipment is the education. Know-how and interaction of all production departments is the base of a successful NNPB-Production.

     

    Heye accompanies its customers for this wide range of areas and activities with long term assistance agreements to achieve their targets. The TAA-team takes a holistic view to all areas of the container glass production.

     

    NNPB – benefits for the glassmaker

    • Less raw material and energy per bottle
    • Machines run faster – more bottles produced
    • Lower unit costs per bottle
    • Better quality and higher value per bottle
    • Higher output, revenue and margin

     

    NNPB – benefits for the filler

    • Better quality, less breakage on filling lines
    • Less weight of the packaging, lower transport costs
    • Filling machines run faster – more bottles filled
    • Lower unit costs per bottle
    • Better appearance, better marketing possibilites
    • Decrease in costs, higher revenue and  margin