How RtOI shop floor analytics increases OEE and manufacturing KPIs in Tirat Zvi factory
Tirat Zvi, Food Production
- Improving Overall Equipment Effectiveness (OEE)
- Understanding production discrepancies
- Shortening production line process
● Improved OEE by ~15%
● Decreased the number of shifts by one shift
● Reduced the time between production and packaging from 4-6 days to 2.5-3 days
● Implemented a 100% Digital Performance management
About Tirat Zvi
The Tirat Zvi plant, established in 1946, is one of Israel’s largest producers and marketers of meat delicacies: pastrami, cold cuts, sausages and other products. In 2000, Tnuva, Israel’s largest dairy producer acquired 50% of the plant’s shares. This partnership allows Tnuva to carry out the distribution, trade and sales of Tirat Tzvi products, thus ensuring speedy and daily delivery to each of its thousands of points of sale spread across the country.
In 2018, Tirat Zvi realized it needed a system that would enable it to collect and analyze data for two of its main production lines: sausage production and packaging. The operation manager knew that machines endured many breaks and stops throughout the shift, but it was difficult to determine where, when and for how long, as all the information was collected and reported manually on paper. It became critical for the operation to know which shifts were more productive, which were less, and the reasons for these discrepancies.
Up until then, machine breakdowns and maintenance problems that occurred during the week were presented and reviewed on the Monday of the following week. Lack of access to critical production issues in real time made it challenging to manage production resources and led to a low OEE.
“For us, machine time equals a million dollars, so we must be able to correct ourselves in real time and online.”
Shai Horesh, Manager of Operational Excellence
Measuring the OEE was another challenge. Since all data was collected manually, it took a full day of data entry work to calculate the OEE, an expensive, time consuming and ineffective process.
Finally, as a producer and distributor of cooked meat products, which are highly sensitive and regulated, it was critical for Tirat Zvi to shorten the time between production and packaging to ensure its packaged meat products were fresh and well before their expiration date when delivered and sold to customers across the country.
In 2018, Tirat Zvi decided to implement Matics manufacturing efficiency platform in both departments, a total of seven production lines. Within a matter of weeks, the Matics system started delivering alerts, reporting problems and production discrepancies and documenting calls for repair – all digitally and in real time.
The viewability and immediate access to production data exposed issues and problems that were not documented prior to using Matics and forced all team members across the plant to deal with the findings. Though challenging and slightly threatening at first, Tirat Zvi employees realized that having Matics at their disposal was helping them do their jobs better.
“The Matics real-time manufacturing analytics implementation was a plug & play. The key was to be consistent, to teach our people how to use the platform and to help them realize it was in their best interest to use it.”
Zohar Elimelech, Chief Information Officer
The bottom line?
Access to online, digital machine data in real time enabled Tirat Zvi to focus its attention on the most critical production issues as they occurred. Within a few months, the number of production lines, that implemented Matics grew from 7 to 10.
Within 6 months of implementing Matics, Tirat Zvi managed to improve its OEE by ~15% and shorten the number of days between the sausage production line and packaging line from 4-6 days to 2.5-3 days, thus ensuring the delivery of fresher products to the market.