Total Production Management reporting can be used to quickly identify problems. The primary statistic ‘OEE’ (Overall Equipment Effectiveness) is calculated as:
OEE = Utilisation x Efficiency x Quality Rate [85% is world class]
Where:
| Field |
Calculation |
Highlights: |
| Utilisation |
Actual machine run time / actual shift time |
Breakdown, setup and adjustment losses |
|
|
Planned non-production and waiting time |
| Efficiency |
Actual Output / Expected Output in running time |
Idling and minor stoppage losses |
|
|
Reduced speed loses |
| Quality Rate |
Actual Quality Output / Expected Quality Output |
Quality defects |
|
|
Start-up yield losses |
The example TPM system shown above was built as a total package in a ‘free-standing’ console.
Included in the box are:
- Computer running a SCAN100-Data software configuration which provides both the database and web-page server making information available to the rest of the organisation.
- PLC with purpose-built code and I/O to gather and pre-process data.
- Touch screen to provide operators with an easy-to-use tool to access valuable information with minimal training.
Simple and speedy installation next to the production line results in minimum downtime.
The TPM software collects machinery data in real time and turns it into valuable information.
This includes:
- Utilisation
- Efficiency
- Quality Rate
- Loss Measurements
- Automatic Line Stoppage Logging
- Fault Logging
- Batch Recording
All these parameters are recorded by batch, shift and day.
The Total Production Management System is designed to be ‘network ready’ with an industry standard network connector so that information from the system is on-line and accessible from anywhere in the factory.
In this modern age, it is important that applications from different suppliers should be able to share information. The system is fully compliant to the latest open standards such as OPC and Microsoft ‘Back Office’.
In practice, this means that data from this system, including items such as the real-time calculation of efficiencies, can be displayed on existing control room systems.
Reporting
All the key information is written in ‘real-time’ to database records. Network tools allow instant access to reports. Reports may be produced automatically or on request.
OEE summary reports speedily highlight line problems:
OEE by Batch for dates: 17/02/99 - 18/02/99
| Batch> |
Utilisation |
Efficiency |
Quality Rate |
OEE |
| 381 |
50.99% |
95.07% |
91.14% |
44.18% |
| 382 |
50.97% |
94.80% |
91.22% |
44.08% |
| 383 |
81.78% |
95.45% |
91.84% |
71.69% |
| 384 |
85.60% |
95.00% |
91.12% |
74.10% |
| Averages |
67.34% |
95.08% |
91.33% |
58.47% |
This report shows a low utilisation figure for batches 381 & 382. Analysis of these batches indicates that these products caused the assembly machine to jam.
This evidence can be used to identify problems, cost losses, re-schedule production, etc.
Managers now have better control of the assembly lines and can answer with confidence:
- How many did we make?
- How much did it cost?
- Can we reach our targets on time?
Other Reports Available include:
| Batches Report-Detailed |
Production by Day |
| Batches Yesterday-Detailed |
Production by Day-Detailed |
| Shifts Yesterday-Detailed |
Productionby Shift |
| Last Months Batch Production |
Shifts by Date |
| Last Months Production by Day |
Stoppage by Batch-Detailed |
| Last Months Shifts |
Stoppage by Day and Machine |
| OEE Monthly |
Stoppage by Day and Reason |
| OEE Percentage |
Stoppage by Machine-Detailed |
| OEE Total Summary |
Stoppage by Reason for Selected Dates-Detailed |
| OEE Batch Select Batches |
Stoppage History by Date-Detailed |
| OEE Batch Select Dates |
Stoppage Log-Full History by Machine |
| OEE by Shift |
Stoppage Log-Full History by Reason |
| OEE by Date |
Stoppage Log-Full History by Shift |
| OEE Shift Summary |
Stoppage Log-Full History by Shift & Machine |
| Utilisation Percentage |
Stoppage Summary by Batch |
| Efficiency Percentage |
Stoppage Summary by Batch & Machine |
| Production by Batch |
Stoppage Summary by Batch & Reason |
| Production by Date and Shift |
Stoppages by Day |
| Yesterdays Batches |
Yesterdays Shifts |
| Yesterdays Production |
Yesterdays Stops |
Information is Power!!!
Contact Hexatec for further information