DataLyzer® OEE
- Overall Equipment
Effectiveness -
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
Goal of this presentation
• Short introduction of TPM and OEE
• Definition of terms
• DataLyzer OEE functionality
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
Total Productive Maintenance
OEE is part of TPM approach.
Original goal of total productive management:
“Continuously improve all operational conditions, within
a production system; by stimulating the daily
awareness of all employees” (by Seiichi Nakajima,
Japan, JIPM)
TPM
An accurate and practical implementation of TPM, will increase
productivity within the total organization, where:
(1) .. a clear business culture is designed to continuously improve the
efficiency of the total production system
(2) .. a standardized and systematic approach is used, where all losses
are prevented and/or known.
(3) .. all departments, influencing productivity, will be involved to move
from a reactive- to a predictive mindset.
(4) .. a transparent multidisciplinary organization is reaching zero
losses.
(5) .. steps are taken as a journey, not as a quick menu.
…… which is exactly the same as in a proper SPC approach
4 Loss types
• There are 4 loss types defined in the
calculation of OEE:
•
•
•
•
Scheduled downtime loss
Unscheduled downtime loss
Performance loss
Quality loss
OEE Definitions
OEE Definitions
• A lot of definitions are used in industry
• Total operations time = plant operating time
• Loading time = Planned production time = run time,
• Running time = Production time = Operating time
• Same definitions are used for different times
• Attempt to standardize in industry:
http://oeeindustrystandard.oeefoundation.org/
See summary in previous slide
OEE
Availability
The availability is the ratio between production time and loading time.
Production time
Downtime loss
Production time / Loading time
The big losses in downtime loss are :
• change over and setup
• breakdowns of the machine
OEE
Performance
The performance ratio is the actual output/ theoretical output or
net operating time /. Production time
Net operating time
Performance
loss
The 2 big losses in performance loss:
• Small stops
• Reduced speed
OEE
Quality
The quality ratio is the productive time / net operating time or good products/total
products .
Productive time
The 2 big losses in quality loss are:
• Startup rejects
• Production rejects
Quality
loss
OEE
OEE = Availability * Performance * Quality
Or
OEE = Good products /
Loading time * Ideal machine rate
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
Time types
Type
P
Name
Production time =
Running time
F
Failure time =
The machine is not having output due to a machine related
Breakdown time
technical problem.
Waiting time =
Idle The machine is not producing output because it has to wait for
time
something (like a setup, or raw material).
Therefore, waiting for a technician during a breakdown is not
Failure time, but Waiting time!
Line restraint time
The equipment cannot generate output because it gets no input
from the line, or cannot give its output to the line.
W
L
U
Unscheduled
N
Not scheduled
Definition
Something is coming out of the equipment, regardless of the
amount, speed or quality.
The equipment is scheduled out of the total operations time, for
reasons beyond the scope of the production team.
Time where there are no operations-activities going on at all.
“The factory is closed, the lights are out“.
Definition problem
• Assignment of time types to downtime loss is always
a big discussion
• Different consultants, companies assign time types to
different losses
• Specific assignment is not so important
• Continuously improve the factors
• DataLyzer is setup flexibly so time types can be
assigned to any loss type so the company can use
their own preferred assignment
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
DataLyzer OEE
• DataLyzer supports 3 different ways of OEE:
1. Manual data entry at end of shift
2. Real time manual entry
3. Real time automatic data entry
• Ad 1: This only requires standard DataLyzer SPC modules.
Downtimes are entered manually at the end of a shift in
standard SPC charts
• Ad 2: This requires DataLyzer OEE module and Shift handler
module
• Ad 3: This requires connection to PLC’s or sensors
DataLyzer OEE
• Basic setup for DataLyzer OEE and real-time OEE is the
same
• Time types are setup as OEE categories
• Downtime reasons are assigned to one of the time
categories
• 2 type of performance loss can be setup
• Reduced speed
• Short stoppages
• Reduced speed will be setup using optional parameters
• Quality loss will be setup using optional parameters
OEE Categories
• Each time type can be assigned to a loss type
• Any number of time types is available
• Flexibility in setup options will accommodate any
preferred setup based on company definitions
Manual data entry OEE
Manual data entry OEE
• Manual entry is done at the end of the shift
• Manual data entry in DataLyzer SPC allows for
monitoring both planned and unplanned downtime.
• OEE calculations are done excluding planned downtime
loss (standard calculations)
• Reduced speed and quality losses are calculated
automatically based on parameter setup
Overview OEE status per productionrun
Manual data entry OEE
• Alarms are given when
• Too much loss in a shift in one category
• Too much loss in a number of shifts (Combined
subgroup) in a category
• OOC Warning is given when loss in a category exceeds
UCL for a combined number of shifts
• In case of alarms or OOC corrective action should be
taken
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
OEE Reporting in
DataLyzer Spectrum
Contents
•
•
•
•
•
•
•
•
•
Introduction
Goal of the meeting
TPM and OEE
Time categories
Manual data entry OEE
OEE reporting in DataLyzer
DataLyzer real-time OEE
Next steps
Questions and answers
DataLyzer real-time OEE
Setup additional options
• Schedules, shifts and holidays can be defined
• User management
• Machine setup and assignment to schedules
• Machine cycle times (rates) per product can be setup
or possibly downloaded from ERP system
DataLyzer real-time OEE
Setup
• OEE can be calculated automatically by extracting PLC
information or productivity information from other
data sources.
• With downtime operator entry might be required to
enter the cause of the downtime
• Different color codes per type of breakdown
• Per breakdown it can be established if technicians are
required to repair the machine
Real-time data entry OEE
Real-time data entry OEE
• Colors can be assigned to the different time types
• User (Technician) can acknowledge arrival and waiting
time, MTTR and MTBF are automatically calculated
• Any number of comments can be entered by
technicians, creating a complete machine logbook
Real-time data entry OEE
• In status screen downtimes and cause of downtime can
be entered. Downtime causes are setup in DataLyzer
Breakdown table
• Breakdown table shows list of breakdowns
• List can be sorted per machine but also of all current
machines which are down
Real-time data entry OEE
• Special tab shows machines in breakdown
• Mail can be send when a machine goes down
• Defects can be entered per run and data will be stored
in standard attribute charts. Total of defects will be
converted to a quality loss per run (see next slide)
• Attribute charts for quality defects is linked to machine
chart
Quality defects and attribute charts
OEE Shift handler
• Separate service aggregates data per shift and creates
input records for parts produced and rejects
• Aggregated data will be stored in attribute control chart
with one subgroup per shift per machine for standard
DataLyzer analysis and reports
• Shift handler changes status of machine at start and
end of the shift
OEE Reports
• All reports can be
sorted or aggregated by
machine, group of
machines, line,
department, time
period, shift or schedule
• Reports available are
uptime, downtime,
OEE, OPE, MTBF and
MTTR and breakdown
overviews.
Future developments
• Service to import breakdown data automatically
from sensors, OPC, PLC’s and other external sources
• Display on external monitors
• Webbased display options including mobile devices
and Androids
Requirements
• DataLyzer OEE runs on SQL Server database. Future
development under Oracle is planned.
• DataLyzer OEE stores data in standard DataLyzer
database.
• DataLyzer OEE is developed in C# and requires NET
Framework 4.0
Support
• DataLyzer OEE can be supported 24 hours per day. With
offices in Asia, Europe and USA we can offer 24 hour
support to world-wide customers.
• First year maintenance is included, after a year
maintenance contract is available for 10 % of the
purchase price. With maintenance contract customers
will receive all new features for free. DataLyzer OEE will
be continuously improved and new features will be
included
Advantages DataLyzer OEE
• Integrated approach for SPC and OEE with strong
reduction in software investment, training and
support
• Large part of setup will be done in standard
DataLyzer which strongly reduces training time
• Statistical analysis possible on OEE data
• SPC Wizard is integrated with OEE
Advantages DataLyzer OEE
• Quality and productivity data integrated in one system
• FMEA can be linked to productivity
• Machine logbook for breakdowns can be linked to quality
data
• Logical 3 step approach
• Manual OEE at end of shift
• Manual real-time OEE
• Automated real-time OEE