04 Tag Standard Graphs Tool Rev 1 Oct 6_2015
14
How to use the tool: 1. AM and PM pillars define the Tag process for each of the 3 Tag types: SHE, Maintenance, and Operator Tags 2. Define the reporting frequency, minimum to be done weekly to ensure proper process management and monthly for pillar reporting. 3. Assign clear responsibilities for tracking and reporting. 4. Define the scope i.e. model machine, model line, total factory of the Tag process. 5. Start tracking and generate the weekly and monthly reports. 6. Use the Tags standard graphs to prioritize activities, course correct, track results and celebrate your succeses. AM PILLAR - TAGS STANDARD AM Ta Ta
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How to use the tool:1. AM and PM pillars define the Tag process for each of the 3 Tag types: SHE, Maintenance, and Operator Tags 2. Define the reporting frequency, minimum to be done weekly to ensure proper process management and monthly for pillar reporting.3. Assign clear responsibilities for tracking and reporting.4. Define the scope i.e. model machine, model line, total factory of the Tag process.5. Start tracking and generate the weekly and monthly reports. 6. Use the Tags standard graphs to prioritize activities, course correct, track results and celebrate your succeses.
Transcript of 04 Tag Standard Graphs Tool Rev 1 Oct 6_2015
How to use the tool:
1. AM and PM pillars define the Tag process for each of the 3 Tag types: SHE, Maintenance, and Operator Tags
2. Define the reporting frequency, minimum to be done weekly to ensure proper process management and monthly for pillar reporting.
3. Assign clear responsibilities for tracking and reporting.
4. Define the scope i.e. model machine, model line, total factory of the Tag process.
5. Start tracking and generate the weekly and monthly reports.
6. Use the Tags standard graphs to prioritize activities, course correct, track results and celebrate your succeses.
AM PILLAR - TAGS STANDARD GRAPH TOOL
AM pillar training and standards
LINKS
Tags data collection matrix
Tags register example (manual data collection)
Monthly data collection
Tag graphs
Revision 1
AM PILLAR - TAGS STANDARD GRAPH TOOL
AM pillar training and standards
LINKS
Tags data collection matrix
Tags register example (manual data collection)
Monthly data collection
Tag graphs
Tags data collection matrixThe Tags data collection matrix shows the following elements:1. The information that needs to be tracked to calculate each of the Tags KAI graphs 2. The recommended AM step where we need to start collecting the information and reporting the KAIs. 3. The minimum frequency at which the data should be tracked to be able to see trends and apply any necessary corrective actions. The factory can decide if they track and display the KAI at a higher frequency i.e. weekly, daily.4. In general the Tags will start at the pilot machine level and then expand quickly into the full factory5. It is recommended to track the Maintenance and SHE - PM related Tags in the existing Computerized Maintenance Management System (CMMS). The factory should decide if the Operator Tags are also track using the CMMS.
# Data collection item
1 Maintenance tags completion rate - cumulative % C1.1 Maintenance tags open - cumulative # C1.2 Maintenance tags closed - cumulative # C1.3 Maintenance tags open # I1.4 Maintenance tags closed # I1.5 Maintenance tags resolution time - average days I
2 SHE tags completion rate - PM related cumulative % C2.1 SHE tags open - PM related cumulative # C2.2 SHE tags closed - PM related cumulative # C2.3 SHE tags open - PM related # I2.4 SHE tags closed - PM related # I2.5 SHE tags resolution time average - PM related hours I
3 Operator tags completion rate - cumulative % C3.1 Operator tags open - cumulative # C3.2 Operator tags closed - cumulative # C3.3 Operator tags open # I3.4 Operator tags closed # I3.5 Operator tags resolution time - average days I4.0 SHE tags completion rate - AM related cumulative % C4.1 SHE tags open - AM related cumulative # C4.2 SHE tags closed - AM related cumulative # C4.3 SHE tags open - AM related # I4.4 SHE tags closed - AM related # I4.5 SHE tags resolution time average - AM related hours I5.0 Total SHE tags completion rate - cumulative % C5.1 Total SHE tags open - cumulative # C5.2 Total SHE tags closed - cumulative # C5.3 Total SHE tags open # C5.4 Total SHE tags closed # C5.5 Total SHE tags resolution time - weighted average hours C
Unit of Measure (UoM)
Input (I) / Calculated (C)
Tags data collection matrix
2. The recommended AM step where we need to start collecting the information and reporting the KAIs. 3. The minimum frequency at which the data should be tracked to be able to see trends and apply any necessary corrective actions. The factory can decide if they track and display the KAI at a higher frequency i.e. weekly, daily.4. In general the Tags will start at the pilot machine level and then expand quickly into the full factory5. It is recommended to track the Maintenance and SHE - PM related Tags in the existing Computerized Maintenance Management System (CMMS). The factory should decide if the Operator Tags are also track using the CMMS.
Step 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 Monthly XStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 MonthlyStep 1 Monthly
What step to start tracking?
What frequency?
KAI - Maintenance Tags
KAI - SHE Tags - PM related
KAI - Operator (AM) Tags
Tags data collection matrix
3. The minimum frequency at which the data should be tracked to be able to see trends and apply any necessary corrective actions. The factory can decide if they track and display the KAI at a higher frequency i.e. weekly, daily.
5. It is recommended to track the Maintenance and SHE - PM related Tags in the existing Computerized Maintenance Management System (CMMS). The factory should decide if the Operator Tags are also track using the CMMS.
KAI - Total SHE Tags
XXXXXX
X XX XX XX XX XX X
XXXXXX
KAI - SHE Tags - AM related
Return to Main page
Calculated indicator - Formulas in place Input data
# Data collection item
1 Maintenance tags completion rate - cumulative % C Step 11.1 Maintenance tags open - cumulative # C Step 11.2 Maintenance tags closed - cumulative # C Step 11.3 Maintenance tags open # I Step 11.4 Maintenance tags closed # I Step 11.5 Maintenance tags resolution time - average days I Step 1
2 SHE tags completion rate - PM related cumulative % C Step 12.1 SHE tags open - PM related cumulative # C Step 12.2 SHE tags closed - PM related cumulative # C Step 12.3 SHE tags open - PM related # I Step 12.4 SHE tags closed - PM related # I Step 12.5 SHE tags resolution time average - PM related hours I Step 1
3 Operator tags completion rate - cumulative % C Step 13.1 Operator tags open - cumulative # C Step 13.2 Operator tags closed - cumulative # C Step 13.3 Operator tags open # I Step 13.4 Operator tags closed # I Step 13.5 Operator tags resolution time - average days I Step 1
4 SHE tags completion rate - AM related cumulative % C Step 14.1 SHE tags open - AM related cumulative # C Step 14.2 SHE tags closed - AM related cumulative # C Step 14.3 SHE tags open - AM related # I Step 14.4 SHE tags closed - AM related # I Step 14.5 SHE tags resolution time average - AM related hours I Step 1
5 Total SHE tags completion rate - cumulative % C Step 15.1 Total SHE tags open - cumulative # C Step 15.2 Total SHE tags closed - cumulative # C Step 15.3 Total SHE tags open # C Step 15.4 Total SHE tags closed # C Step 15.5 Total SHE tags resolution time - weighted average hours C Step 1
6 Total tags completion rate - cumulative % C Step 16.1 Total tags open - cumulative # C Step 16.2 Total Tags closed - cumulative # C Step 1
Monthly Tags Data Collection
Unit of Measure
(UoM)Input (I) /
Calculated (C) What step to
start tracking?
B22
Barragan, Felipe: Cumulative = Sum of time to replace components as part of all planned maintenance tasks executed during the specified period of time
B25
Barragan, Felipe: The Machine ledger KAI is used factory wide to show the expansion of the machine ledger application as we expand our PM activities from our model machine into AA-A-B-C as determined by CD. The figures on this example show the expansion of the machine ledger into more machines
Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15
Monthly 87.5% 90.4% 86.5% 88.5% 92.4% 93.2% 96.1% 97.8% 98.6%Monthly 200 415 665 870 1050 1175 1275 1365 1425Monthly 175 375 575 770 970 1095 1225 1335 1405Monthly 200 215 250 205 180 125 100 90 60Monthly 175 200 200 195 200 125 130 110 70Monthly 5.2 4.8 7.5 7.0 6.0 3.5 3.0 2.0 1.9Monthly 90.9% 93.6% 98.6% 98.9% 99.1% 99.2% 99.3% 100.0% 99.3%Monthly 22 47 69 92 111 126 137 145 152Monthly 20 44 68 91 110 125 136 145 151Monthly 22 25 22 23 19 15 11 8 7Monthly 20 24 24 23 19 15 11 9 6Monthly 72 66 62 60 58 55 52 48 46Monthly 83.3% 90.0% 96.7% 96.3% 96.4% 96.9% 98.4% 98.2% 98.0%Monthly 30 70 120 160 195 228 253 277 304Monthly 25 63 116 154 188 221 249 272 298Monthly 30 40 50 40 35 33 25 24 27Monthly 25 38 53 38 34 33 28 23 26Monthly 3.0 3.5 3.0 2.5 2.4 2.5 2.3 2.5 2.3Monthly 90.0% 94.7% 94.8% 96.0% 97.8% 98.1% 99.2% 99.2% 99.3%Monthly 20 38 58 75 91 105 118 130 143Monthly 18 36 55 72 89 103 117 129 142Monthly 20 18 20 17 16 14 13 12 13Monthly 18 18 19 17 17 14 14 12 13Monthly 84 80 76 74 70 68 64 62 60Monthly 90.5% 94.1% 96.9% 97.6% 98.5% 98.7% 99.2% 99.6% 99.3%Monthly 42 85 127 167 202 231 255 275 295Monthly 38 80 123 163 199 228 253 274 293Monthly 42 43 42 40 35 29 24 20 20Monthly 38 42 43 40 36 29 25 21 19Monthly 78 72 68 66 64 61 59 56 56Monthly 87.5% 90.9% 89.3% 90.8% 93.8% 94.5% 96.9% 98.1% 98.6%Monthly 272 570 912 1197 1447 1634 1783 1917 2024Monthly 238 518 814 1087 1357 1544 1727 1881 1996
Monthly Tags Data Collection
End of Step 1
End of Step 2
End of Step 3
What frequency?
Return to Main page
G6
Barragan, Felipe: Enter the date when you started your PM step 1 activities
Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16
98.8% 99.1% 99.0% 99.0% 99.1% 99.0% 98.9% 98.9% 99.0% 99.1%1475 1515 1555 1595 1630 1672 1701 1736 1761 17911457 1501 1539 1579 1615 1655 1683 1717 1743 1774
50 40 40 40 35 42 29 35 25 3052 44 38 40 36 40 28 34 26 311.3 1.2 1.0 0.9 0.8 1.0 0.9 0.8 0.6 0.5
99.4% 100.0% 100.0% 99.4% 99.4% 100.0% 100.0% 100.0% 100.0% 100.0%158 164 169 173 178 181 183 185 188 188157 164 169 172 177 181 183 185 188 188
6 6 5 4 5 3 2 2 3 06 7 5 3 5 4 2 2 3 0
46 44 42 40 39 38 36 35 34 3298.8% 98.3% 98.1% 97.7% 98.4% 99.1% 99.0% 99.1% 98.8% 99.2%
329 349 371 399 434 466 496 528 563 593325 343 364 390 427 462 491 523 556 58825 20 22 28 35 32 30 32 35 3027 18 21 26 37 35 29 32 33 322.2 2.2 2.1 2.0 1.9 1.8 1.8 1.7 1.6 1.6
98.7% 99.4% 99.4% 99.5% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%155 166 176 185 193 200 207 213 220 226153 165 175 184 193 200 207 213 220 22612 11 10 9 8 7 7 6 7 611 12 10 9 9 7 7 6 7 656 53 51 49 48 46 44 40 36 34
99.0% 99.7% 99.7% 99.4% 99.7% 100.0% 100.0% 100.0% 100.0% 100.0%313 330 345 358 371 381 390 398 408 414310 329 344 356 370 381 390 398 408 41418 17 15 13 13 10 9 8 10 617 19 15 12 14 11 9 8 10 652 50 48 47 45 43 42 39 35 3498.8% 99.0% 98.9% 98.9% 99.1% 99.2% 99.1% 99.1% 99.1% 99.2%
2117 2194 2271 2352 2435 2519 2587 2662 2732 27982092 2173 2247 2325 2412 2498 2564 2638 2707 2776
Monthly Tags Data Collection
End of Step 4
Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17
99.1% 99.1% 99.1% 99.2% 99.2% 99.2% 99.2% 99.2% 99.2% 99.3%1823 1848 1871 1891 1906 1926 1943 1958 1974 19921806 1831 1855 1875 1890 1910 1927 1942 1959 1978
32 25 23 20 15 20 17 15 16 1832 25 24 20 15 20 17 15 17 190.4 0.5 0.3 0.4 0.3 0.5 0.4 0.3 0.3 0.3
100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%191 193 193 193 193 193 195 196 196 197191 193 193 193 193 193 195 196 196 197
3 2 0 0 0 0 2 1 0 13 2 0 0 0 0 2 1 0 1
30 29 28 26 25 24 22 21 19 1799.0% 98.8% 99.0% 99.3% 99.2% 99.3% 99.3% 99.3% 99.3% 99.3%
628 665 705 740 777 807 827 845 860 877622 657 698 735 771 801 821 839 854 87135 37 40 35 37 30 20 18 15 1734 35 41 37 36 30 20 18 15 171.5 1.4 1.2 1.1 1.1 1.0 0.9 0.9 0.8 0.7
100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%231 235 239 244 247 251 253 255 256 257231 235 239 244 247 251 253 255 256 257
5 4 4 5 3 4 2 2 1 15 4 4 5 3 4 2 2 1 1
32 28 25 24 20 18 16 15 17 14100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%
422 428 432 437 440 444 448 451 452 454422 428 432 437 440 444 448 451 452 454
8 6 4 5 3 4 4 3 1 28 6 4 5 3 4 4 3 1 2
31 28 25 24 20 18 19 17 17 1699.2% 99.1% 99.2% 99.3% 99.3% 99.3% 99.3% 99.3% 99.4% 99.4%
2873 2941 3008 3068 3123 3177 3218 3254 3286 33232850 2916 2985 3047 3101 3155 3196 3232 3265 3303
End of Step 5
End of Step 6
Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17
99.3% 99.4% 99.4% 99.3% 99.3% 99.3% 99.3%2006 2019 2037 2052 2068 2081 20951992 2006 2024 2038 2054 2067 2081
14 13 18 15 16 13 1414 14 18 14 16 13 140.2 0.3 0.3 0.3 0.4 0.2 0.2
100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%197 197 199 199 199 200 201197 197 199 199 199 200 201
0 0 2 0 0 1 10 0 2 0 0 1 1
14 12 10 9 8 8 899.3% 99.4% 99.6% 99.6% 99.7% 99.7% 99.8%
890 900 910 922 930 940 949884 895 906 918 927 937 94713 10 10 12 8 10 913 11 11 12 9 10 100.7 0.6 0.7 0.8 0.7 0.6 0.5
100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%259 260 262 264 265 265 266259 260 262 264 265 265 266
2 1 2 2 1 0 12 1 2 2 1 0 1
13 12 9 10 9 8 7100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%
456 457 461 463 464 465 467456 457 461 463 464 465 467
2 1 4 2 1 1 22 1 4 2 1 1 2
13 12 10 10 9 8 899.4% 99.5% 99.5% 99.5% 99.5% 99.5% 99.5%
3352 3376 3408 3437 3462 3486 35113332 3358 3391 3419 3445 3469 3495
End of Step 7
AM pillar - Tags standard KAI graphs
Total Tags by type
To start in Step 1 - step start and end lines have to be updated manually
Maintenance Tags SHE tags - PM related
Operator Tags SHE tags - AM related
Total SHE Tags - Considers all SHE - Tags (PM and AM related)
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Maintenance Tag performance - cumulative
Maintenance tags open - cumulative Maintenance tags closed - cumulativeMaintenance tags completion rate - cumulative
# of
Mai
nten
ance
Tag
s - c
umul
ative
Com
pletti
on ra
te -
%
End step 1 End
step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
50
100
150
200
80%
85%
90%
95%
100%
SHE Tags - PM related performance - cumulative
SHE tags open - PM related cumulative SHE tags closed - PM related cumulativeSHE tags resolution time average - PM related SHE tags completion rate - PM related cumulative
# of
SH
E Ta
gs P
M re
late
d cu
mul
ative
/ R
esol
ution
tim
e -
hour
s
Com
pleti
on ra
te -
%
End step 1
End step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Return to Main page
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
200
400
600
800
1000
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Operator Tag performance - cumulative
Operator tags open - cumulative Operator tags closed - cumulativeOperator tags completion rate - cumulative
# of
Ope
rato
r Tag
s - c
umul
ative
Com
pletti
on ra
te -
%
End step 1 End
step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
50
100
150
200
250
300
80%
85%
90%
95%
100%
SHE Tags - AM related performance - cumulative
SHE tags open - AM related cumulative SHE tags closed - AM related cumulativeSHE tags resolution time average - AM related SHE tags completion rate - AM related cumulative
# of
SH
E Ta
gs A
M re
late
d cu
mul
ative
/ R
esol
ution
tim
e -
hour
s
Com
pleti
on ra
te -
%
End step 1
End step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
50
100
150
200
250
300
350
400
450
500
80%
85%
90%
95%
100%
Total SHE Tags - cumulative
Total SHE tags open - cumulative Total SHE tags closed - cumulativeTotal SHE tags resolution time - weighted average Total SHE tags completion rate - cumulative
# of
Tot
al S
HE
Tags
cum
ulati
ve /
Res
oluti
on ti
me
- hou
rs
Com
pleti
on ra
te -
%
End step 1
End step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Jan-15
Mar-15
May-15
Jul-15
Sep-15
Nov-15
Jan-16
Mar-16
May-16
Jul-16
Sep-16
Nov-16
Jan-17
Mar-17
May-17
Jul-17
Sep-17
Nov-17
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Total Tags by type - cumulative
Maintenance tags open - cumulative Operator tags open - cumulativeTotal SHE tags open - cumulative Total tags completion rate - cumulative
# of
Tot
al T
ags
- cum
ulati
ve
Com
pletti
on ra
te -
%
End step 1 End
step 2
End step 3
End step 4
End step 5
End step 6
End step 7
Tags register exampleThe Tags register is used to track the tags until their completion. This template is to be used only when there is NOT a computerized Tag tracking system (i.e. CMMS)It is the factory decision to use one Tags register template per type of Tag (SHE, Maintenance, Operator) or one for all Tags. The main purpose of the Tags register is to track their completion and identify improvement trends
Information to be filled out by the person who opens the Tag Information to be filled out by person who closes the Tag
Tag # Date NameTag type
Area / Line MachinePriority
Brief abnormality description Implemented solution Date NameSHE Maint. Operator A B C
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