Redzone University
“Redzone is truly empowering not only our supervisors, but also our operators to get the performance they need on their lines. It’s turbo charged our process!”
With an average of 20%+ increase in productivity and efficiency, many of our customers can produce more in less time. Significantly increase plant productivity by 26% in 90 days by activating your frontline teams. Working double shifts and weekends are no more when you leverage Redzone’s overall equipment effectiveness software!
Everyone knows the score and competes to win the day. Enable frontline teams to adapt in the moment with a sense of urgency and bias for action.
Working hard doesn’t always mean working effectively. OEE software provides feedback to factory teams about minutes of downtime, slow-running lines, and scrap. Redzone’s OEE dashboards provide this information by line, minute by minute, and share it in real time factory-wide through easy to understand dashboards. Improvement begins when the opportunities are highlighted.
Everyone knows the score with eye-popping real-time dashboards built specifically for factory teams using efficient data collection and advanced software from simple sensors, IIoT devices, or MES integration. This data is combined with context from your frontlines to make KPIs actionable: throughput, OEE, labor efficiency, downtime, scrap create a link from the shopfloor to the top floor. Give everyone real-time visibility to real-time data so they know if they are winning or losing at all times.
Create an army of frontline problem solvers.
Intuitive in-app reporting tools and advanced analytics help identify systemic problems. The Redzone digital kaizen allows frontline teams to conduct root cause analysis using 5-why and fishbone diagrams; then, score solutions based on impact, cost, and ease. Teams implement high impact improvements and track results to close the loop, ensure sustainability, and maximize
OEE software is a digital tool used by manufacturers to track Overall Equipment Effectiveness (OEE) — a key performance indicator that measures how effectively a manufacturing operation is running. Visibility of OEE is visibility into the opportunities within every manufacturing process.
OEE (Overall Equipment Effectiveness) is a standard industry method of calculating productivity.
There are three components to OEE.
Availability % – percentage of the scheduled line time that the line is actively running product
Performance % – actual run speed as a percentage of the theoretical maximum run speed
Quality % – percentage of total parts produced as good sellable parts (excludes scrapped or reworked parts)
The standard calculation for OEE is:
Availability % x Performance % x Quality % = OEE
e.g.: 95% x 95% x 95% = 85.7% OEE
OEE provides immediate understanding of the total available opportunities of a given manufacturing process versus the percentage of those opportunities effectively used to make good product. It’s a universal measure, applicable to any process and any facility size. Each of the three components describes a different type of process loss. Non-productive minutes are reflected in the Availability %. Products that run more slowly than ideal are reflected in the Performance %. And when lines struggle with first pass quality, that will be reflected in the Quality %.
Very little infrastructure is required to generate and share meaningful data to be shared with your manufacturing team in real time. Factories are able to procure, install, and validate their systems in 6 – 8 weeks. Any manufacturing process can be included in Redzone and measured against meaningful targets. The most commonly deployed device configuration for a process is an external sensor connected to an IIoT PLC which is connected via ethernet to a standalone automation server. Information is then sent wirelessly to display devices like TVs and iPads. Redzone is compatible with many integrations including pulling data directly from ERPs, pre-existing networked PLCs, and IIoT sensors. As part of your Redzone evaluation process, a Redzone Solutions Consultant will evaluate your factory and current IIoT infrastructure and provide you with a full automation scoping and list of required equipment.
Total Productive Maintenance (TPM) is a comprehensive maintenance approach focused on maximizing equipment effectiveness by involving all employees in proactive and preventive maintenance activities. Overall Equipment Effectiveness (OEE), on the other hand, is a key performance metric used to measure manufacturing productivity by evaluating equipment availability, performance, and quality. TPM is a strategy aimed at improving equipment reliability and efficiency and increases the engagement of Operators in the overall maintenance of equipment. TPM initiatives help improve the individual components of OEE calculations: reducing unscheduled downtime creates a higher Availability %; improving equipment functions will allow products to run closer to optimal run rates and increase the Performance %; and when each piece of equipment is optimized, rework and scrap are decreased which increases the Quality %. OEE tracking quantifies the actual effectiveness of TPM and ensures targets achieved are targets maintained.
Redzone’s Connected Workforce Solution is scaled to fit factories of every size. As part of your Redzone evaluation, you’ll be provided with a full cost analysis and projected ROI. Redzone provides a rapid time to value, with most companies seeing a full ROI in only 4 to 6 months.
Contact us and let's begin empowering your frontline and growing your bottomline.
