Kimberly Clark is a part of the Kimberly Clark Corporation worldwide group. It produces hygienic disposables. Especially the Huggies are famous in the Czech Republic. They are produced on several production lines in the Jaroměř plant.
Project: Preventive Maintenance Information System implementation, Kimberly Clark s.r.o. Jaroměř, September 2005
Situation
The production lines require large-scale maintenance of several thousands spare parts. The non-stop production (7 days a week, 24 hours a day) is provided by tens of workers from several divisions. The MS-Excel maintenance records were difficult to evaluate. It was complicated to get complex data for periodical maintenance planning because of the high number of the production lines spare parts and the production perations.
Solved issues
On account of the number of maintained production lines spare parts it was necessary to implement the system in successive steps. In the first step the part of the program producing the line structure definition (parts of the line and maintenance tasks definitions relevant to the parts) was implemented.In this program designated specialists worked out the chosen production line description. In the second step jobs performed on the line were provided on the maintenance documents. Stepwise the provision of other maintenance documents (requisition forms and orders) was added. Based on experience gained within the implementation of the first line other lines were worked into the system.
Results
Thanks to the data acquisition on the maintenance carried out the data for maintenance planning are being specified. The production devices and the maintenance operation are more precisely described in the system.The description is available to anybody who needs it. Thanks to the implementation of SG DMS document management system implementation datasheets containing the documentation are joined to the equipment data. There are system evaluations tools available which enable sequentially specify the standard time needed for the particular maintenance action. Software controlled preventive maintenance is being implemented.The system provides automated tools for mass maintenance tasks entry and reporting. The system automatically generates permanent maintenance orders for frequent actions, offers tasks that should be performed. The system allows flexible changes of planned actions and helps in time utilization of both planned and unplanned downs to perform effective actions based on the choice of the permanent action list
Customer
Ing. Miloš Kotermann, technical support manager, Kimberly Clark s.r.o.: „In the first phase of the software controlled preventive maintenance management system project implementation we had to solve many difficulties relevant to the complication of our production devices. The effort of their detailed description is now being evaluated in everyday use of the system. We are getting data for a flexible production lines preventive maintenance management system by using the continuous specification of the particular spare parts periodical maintenance data. The objective of the system implementation is the improvement of the maintenance actions organization, minimizing of delays and increasing of capacity utilization of our production devices.“
Project : On-line production reporting 2004
Situation
The shortage of information about the process of production for the management Inaccurate information about the shifts Complicated collecting and treatment of information about the results of production in all assembly lines. Before installation of On-Line Production Reporting, the valuation of results of production in Kimberly Clark s.r.o. was done by hand written copy of values from counters on the assembly lines. This system was quite complicated and inaccurate thus the management gained the information about the process of production the next day at the best.
Solved issues
This method of solution collects data from the counters located at the assembly lines and their controlling computers. These data collected to PLC are handed by LAN network on to the central database server. The application built upon this database server makes data available for the intranet. The access to the information needs no installation on the user computer. Persistence of this collecting system against HW failure (network or server) is guaranteed for eight hours.
Results
On-demand accessibility of information about the process of production is possible from any company computer.Every manager or technician of the company has immediate access to data about the process of production. Accurate and reliable information directly from the assembly line.
Information gained by direct access to machines are reliable, there are no problems with the human element inaccuracy, typing errors, difficulty and time delays. Information for evaluation of the process of all shifts. The data are stored in the central database server to evaluate the process of all shifts retrospectively.
Ing. Vladislav Král, manager of the project On-line Production Reporting, Kimberly Clark s.r.o.: „The main benefit of this project was the immediate knowledge of all managers about topical proces of production in all assembly lines of our plant. Now the data are accurate and permanently available to everybody.“