Project Charter
Project title: Implementing the 5 levels of control on PET Line 1
Prepared by: John Smith
Background to the project/current state:
(Include KPI's)
A year ago Line 1 was upgraded with a new filler,
bottle conveyors, labeller and packer.
Although the updated equipment met its
acceptance trial targets it is believed that
increased line utilisation and equipment reliability
can be achieved through line control
implementation.
Line OEE is currently at 65%.
Criteria of success:
Audit documents completed including reaction
timings, for all pack types and bottle sizes.
Improvement opportunities identified/prioritised
and all achievable improvement work complete.
Re-audit completed and improvement results
identified.
Example
Assumptions:
No reasonable capital expenditure will be denied,
however the focus should be on extracting the
most from the hardware and software
functionality that currently exists.
A line control team will be formed with all the
required technical skills available.
Any line downtime that is required will be factored
into the production plan and provided.
Volume available to test the impact of changes.
Guidelines/ground rules:
Team will present initial audit results and
improvement actions within 2 weeks of project
start.
Weekly progress updates will be issued via email.
Any actions requiring capital investment will be
reviewed with ops manager for sign off.
Key dates in the project/outline plan:
Initial review to be held in week 4
Update email issued by 4:00pm every Friday
New product trials week 10
Evaluation (actual results vs goal):
A line control score of 92% was achieved within
7 months. Remaining 8% not achievable due to
older equipment functionality.
Line OEE increase measured as 5.2% largely
achieved through cascade restart from packer to
labeller and labeller to filler. Accumulation was also
Date: 1/1/2015
Version: 1.0
Desired outcome and expected results:
(Include KPI's & Potential cost savings "SMART")
90%+ line control score within 6 months
5% increase to line OEE
Increased equipment reliability and wear reduction
Minimised impact of energy saving functionality
on critical machine restart following a stoppage.
Consequences of failure:
Increase in line utilisation not achieved
Line reliability and wear reduction opportunities
not identified
Zero reduction in machine MTBF through line
control.
Constraints:
Line control team members will be expected on
average to devote 70-80% of their time to this
project within the first month and 30-50%
thereafter.
Volume for certain bottle sizes and or pack types
not being present
Tools to be applied:
5 levels of control methodology
Siemens PLC programming skills
Key project personnel/support required:
Key: Team leader (days)
Automation engineer/Line STO
Support: Line control consultant
Machine OEM engineers
Evaluation score:
How well did I perform in this project?
Score: 9 (Scale of 0-10)
How well did the team perform?
Score: 9 (Scale of 0-10)
maximised through sensor adjustment.