1. ABC Group Management Meeting: ANDON SYSTEM ANDON ABC Group Manufacturing

2. ABC Group Management Meeting: ANDON SYSTEM ANDON: PLANT DISPLAY Typical Display in Plant Location Photo displays one of multiple data screens that will cycle through. Note green for in control and red for out of pre-set parameters.

3. ABC Group Management Meeting: ANDON SYSTEM ANDON 1.THREE PHASES –CALL FOR HELP –PRODUCTION MONITORING –PROCESS MONITORING

4. ABC Group Management Meeting: ANDON SYSTEM PHASE 1: CALL FOR HELP HMI unit installed on each assembly line –Individual IP address –Expandable to accommodate all three phases –Plant Responsibility Pre-wire plant with Network Cables and Power at selected location Install software in HMI unit and mount at assembly process Locate and Install network PC with Indusoft Software Locate and mount Audio and Visual Displays –Group Support Create Screens for HMI Develop tracking system with MySQL database Customise to Individual Plants Provide files for installation on Server and HMI Phone support and Remote connection to PC

5. ABC Group Management Meeting: ANDON SYSTEM Call For Help Main Screen Typical HMI Call for Help Screen Plan to introduce a second set of call buttons.

6. ABC Group Management Meeting: ANDON SYSTEM Call for Technician Operator will press the screen to initiate a Call for Help A counter will immediately start tracking the response time. An Audio and Visual indicator will be sent to the display panels throughout the plant

7. ABC Group Management Meeting: ANDON SYSTEM Indicator Flashes Red After a Preset Time has Passed With No Response Plant will set a response time target. Data will be analysed to monitor performance to this target. Target will be lowered once performance is met. This allows the plant to monitor the effectiveness of the system and measure their ongoing improvements.

8. ABC Group Management Meeting: ANDON SYSTEM Multiple Calls Can Be Made

9. ABC Group Management Meeting: ANDON SYSTEM Technician has Closed Issue Material Handler Flashing Red

10. ABC Group Management Meeting: ANDON SYSTEM On Line Viewing of Service Response Time

11. ABC Group Management Meeting: ANDON SYSTEM By Date, Shift, Who, Time

12. ABC Group Management Meeting: ANDON SYSTEM Select Date from Calendar

13. ABC Group Management Meeting: ANDON SYSTEM Select Shift from Drop Down Menu

14. ABC Group Management Meeting: ANDON SYSTEM Sort by who was called

15. ABC Group Management Meeting: ANDON SYSTEM Select by Minimum Response Time

16. ABC Group Management Meeting: ANDON SYSTEM To Save Processor Capacity Screen Does Not Update Until Refresh Button Selected

17. ABC Group Management Meeting: ANDON SYSTEM Screen Refreshed

18. ABC Group Management Meeting: ANDON SYSTEM CALL FOR HELP: Next Steps 1.Add Second Column to Call For Help Screen –Add ability to select machine down or up i.e. select Matl Handler (Machine Up) when low on components, upgrade to Matl Handler (Machine Down) when components out of stock and production stopped –System may be able to prioritize call –Allows for clear recording of downtime 2.Potential to prioritize Call based on machine priority i.e. Plant Manager (or designate) assigns a priority listing to all jobs running. System can redirect response based upon this priority list. 3.Downtime Tracking –Respondent to log in when they arrive Separate log for time to respond versus time to resolve issue –Respondent to log out and enter downtime code when issue resolved 4.Standards –All plants will develop a standard for response time –System will monitor time and indicate out of standard responses –Software will track and produce reports in order to allow plants to focus on issues –Once standard is met, plant will be challenged to reduce time thus ensuring ongoing continuous improvement.

19. ABC Group Management Meeting: ANDON SYSTEM PHASE 2: Production Monitoring 1.Utilize Same HMI unit as Call For Help System 2.Plants must show evidence that they are utilizing CFH system effectively and pass the ABC Cat audit for TPS foundation implementation prior to moving to Phase 2 3.PRODUCTION MONITORING –Allows for on line reporting of all production –Operator/Line Leader (TBD???) will select part from menu Selection of part will call up a recipe for that part which will be used in OEE calculations Variations from recipe may be entered (labour, cycle) –Set-up will record changeover time –Reporting of Good Parts Scrap (Including Reason Code) Downtime (Reaction Time, Reason Code, Respondent Identity (TBD)) –Automatic OEE Calculation –Data export to CMS at Preset Interval (Hourly ?)

20. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Line Selection Supervisory screen on HMI allows for viewing of any line on the production floor.

21. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Main Screen Efficiency Calculation has already been changed to OEE

22. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Enter Good Part Manually Calculation based upon part recipe stored in database.

23. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Multiple Part Reporting

24. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: 5 Good Parts Added

25. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Enter Scrap and Reason

26. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Hit Report Scrap to update

27. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Scrap Reported

28. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Downtime and Reason

29. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Hit Report Downtime

30. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Downtime Reported

31. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Scrap Log

32. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Refreshed Scrap Log

33. ABC Group Management Meeting: ANDON SYSTEM Production Monitoring: Next Steps 1.Change Efficiency to OEE: Completed 2.Develop Main Supervisory Screen –Ability to review any machine in facility or group (customisable) –Create part selection screen by machine (WHO? Supr or OP) Database of recipes by machine and part number –Enter changes to standard recipe (Supervisor only) 3.OEE calculation –Based upon recipe –Need secondary visual indication at line to allow operators to see performance to standard 4.Report Production to CMS –Develop output file and system to ensure regular reporting. 5.Personnel Lists –Creation of for tracking downtime –Maintaining and updating list

34. ABC Group Management Meeting: ANDON SYSTEM Phase 3: Process Monitoring 1.Plants will need to demonstrate active use of Production Monitoring prior to implementing Process Monitoring 2.Recipe for part will call up a preset list of parameters –Parameters will have ranges for in control –HMI will monitor various machine parameters Out of control parameters will have an escalation system. –Parameter examples Cycle time Part weight Machine Controls Temperatures Motors Silos Blenders Etc.

35. ABC Group Management Meeting: ANDON SYSTEM Process Control: Blenders

36. ABC Group Management Meeting: ANDON SYSTEM Process Control: Dryers

37. ABC Group Management Meeting: ANDON SYSTEM ANDON: Next Steps 1.Select Compatible HMI unit2 weeks 2.Complete Call for Help Screens4 weeks 3.Create MySQL database for retention of data2 weeks 4.Develop Production Reporting6 weeks 5.Create Downtime/Scrap Codes and databases3 weeks 6.Set-up reporting to CMS2 weeks 7.Develop Process Monitoring12 weeks 8.Plant Level Development –Customise Call for Help3 days –MySQL database1 week –Install hardware3 weeks –Install software and set-up IP addresses2 weeks –Set-up Indusoft Server1 week