CASE STUDY:
CooperVision®
How CooperVision® one of the
world’s leading manufacturers
of contact lenses, achieved
OEE gains of over 20% by
following the data.
ROB GEORGE
Asset Care Manager, CooperVision
Part of the Cooper Company, Inc. (NYSE: COO), headquartered in Pleasanton, California, CooperVision is a $1 billion dollar global business with
7,800 staff and sales in over 100 countries. It is one of the world’s largest contact lens manufacturers.
I’m the Asset Care Manager at CooperVision UK. My core objectives are simple:
TO INCREASE
TO REDUCE
WHILE MAINTAINING WORLD
OUTPUT
COST PER UNIT
CLASS QUALITY LEVELS
Over the past four years I have taken the business on a journey that we now call “The Science of Manufacturing”. OEEsystems International is a key partner
on this journey. In 2012, we chose OEEsystems because of their expertise, experience and unique software solution PerformOEE™, which powers real-time
performance improvement. Hamble, Southampton is where we manufacture CooperVision’s range of contact lenses.
We initially installed PerformOEE™ on just one production line.
THREE initial improvement objectives:
1
Measure and establish the reason for significant variations in our batch changeover times, while developing a WIN culture in our Production Teams.
2
Identify and deeply understand the cause of bottlenecks within our manufacturing process.
3
Improve the visibility of yield losses and unplanned downtime.
IDENTIFYING THE PROBLEM
AND IMPLEMENTING THE SOLUTION
PROBLEM:
We couldn’t supply our growing market share using current platforms. We had run out of space to install new platforms. We had to think differently. The
baseline OEE metric demonstrated we didn’t need new factories or lines.
SOLUTION:
Using PerformOEE™, in two years we achieved:
5%
29%
20%
INCREASE
INCREASE
INCREASE
Increase in Yield
Increase in Volume
Increase in OEE
68%
18%
14.2
REDUCTION
REDUCTION
DAYS PAYBACK
in Unplanned
in Cost per Unit
Payback on PerformOEE™
Downtime, falling
every 14.2 days.
from 13.7% to 4.4%.
DELIVERING AUTOMATED, ACCURATE,
INTELLIGENT, REAL-TIME DATA
The software’s powerful root-cause analytics immediately highlighted and confirmed that we had substantial variations in the time it took to
complete a batch change. While acknowledging that speed is important it is not always the optimum.
Based on the intuitive information provided – using the principle of “Follow the Data” – we reorganized our teams and worked with them to remove the
variation, setting a standard time for batch changeovers. This gave us an immediate increase in our Overall Equipment Effectiveness (OEE) score and also
improved our Single Minute Exchange of Dies (SMED) score because of better monitoring.
The next step was to address issues with equipment performance. Again PerformOEE™ gave us unprecedented visibility and process control by highlighting
problems in real-time, enabling the right response. It revealed how our machines were actually performing. The system identified key signatures for failure
that were unique to an individual line, as well as generic reasons for failure across all lines. When these basic root-cause losses were addressed, the result
was another lift in our OEE score.
“The software was able to identify and prioritise a continuous
stream of live performance issues and identify root-cause losses for
our teams to focus on and fix.”
A further benefit was that the software provided a clear understanding and granular breakdown of unplanned downtime – by line, product and shift – so we
could work out our capability. As a result we significantly reduced our unplanned downtime.
We were able to review the lines and compare them, thus developing a robust process to sustain our improved OEE. We now have better organization of our
teams, with critical modules and bottlenecks being monitored and highlighted. As a result we have had a significant decrease in unplanned downtime and
yield loss. Overall we have increased our OEE score by over 20% and the system pays for itself every 14.2 days – and we believe there is more to come.
Following the data has been key to this achievement. PerformOEE™ is now being installed at other CooperVision sites worldwide.
“Overall we have increased our OEE score by over 20% and the
system pays for itself every 14.2 days – and we believe there is more to come.”
OEE Data Driven Technical and Cultural Development
WHY IMPLEMENT
OEE Bottleneck Batch Change Loss on Peel
OEE%
100%
PerformOEE?
90%
1
2
3
1 By empowering local teams – transferring accountability for batch
80%
changeovers and embedding a WIN culture – we got faster responses to
breakdowns and less variation, resulting in 5% more lenses coming off
70%
the line. OEE went up to 65%.
OUTPUT INCREASE
80% AVERAGE OEE
60%
2 Next we developed the Production and Manufacturing Support Engineer
OUTPUT INCREASE
teams, optimized the line set-up, put in local continuous improvement (CI) and started using reliability-centered maintenance (RCM). The
72% AVERAGE OEE
50%
OUTPUT INCREASE
results? A further 7% increase in output – from reduced variation and
65% AVERAGE OEE
40%
increased process capability – bringing OEE to 72%.
5% Extra Lenses come
7% Extra Lenses come
8% Extra Lenses due to
WHERE ARE WE?
off the bottom due to
off the bottom & top
Capability Improvements
3 As a final step in the pilot, we turned our attention to continuous
HIGH VARIATION
less variation, ultimate
combined due to less
on the top and further
process capability
variation and increased
reductions in Variation
improvements generated from using the pareto of losses to prioritize
60% AVERAGE OEE
remains the same
process capability
off the bottom
actions. We achieved a further 8% increase in output – again through
a combination of reduction in variation and improvement in process
0 – 6 Months
6 – 12 Months
12 – 24 Months
capability – bringing average OEE to 80%.
“In all, we achieved a 29% increase in output and a corresponding 20% increase in OEE. This success led us to implement PerformOEE™ across all our lines here in Southampton.”
PRINCIPLE: FOLLOW THE DATA
“Follow the data” means being guided by PerformOEE data analytics as to your next appropriate actions. Pet projects have no place on the path
to Operational Excellence.
Before we brought OEEsystems International on-board we calculated OEE manually on spreadsheets. It was a good start and gave us an understanding of how OEE works as a key manufacturing performance management tool.
However this approach was unsustainable, as there was significant effort, time and cost involved in collecting the data manually and, while the spreadsheets
were useful, they were not intuitive and powerful enough to provide us with in-depth real-time insights into our manufacturing process issues.
By the time we had collected and were ready to analyse the data, it was too late. The data was time-lagged and the loss was historic. We knew we needed
to source both OEE software and the expertise that could be a game-changer for us. An extensive global search brought us to OEEsystems International and
PerformOEE™.
This was our starting point on Line 13 chosen for the pilot – high variation in batch changeover times, with a 60% average OEE.
“Working with OEEsystems International has been a very positive
experience for CooperVision UK. We have a great collaborative
relationship and are working together to co-create the next generation of manufacturing excellence software. At the core of this is what we call “The Science of Manufacturing”. ”
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