An off the shelf system for Downtime and
OEE Reporting
Agenda
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Introduction
The Business Case
Technology
Trends in Technology
Solution Description
ROI Sample Case
Road Map
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Introduction
• RtDuet is
– Real Time Downtime, Uptime and Event
Tracking Software for PI Users.
– Manufactured by ADM Systems Engineering
Ltd.
– Built on Microsoft .net and OSIsoft technology
– Simple, easy to install, use and understand
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The Business Case
• Investments in automated Downtime Reporting
typically enjoy a payback period of 4 months or
less.
• KPI’s like Downtime, Utilized Machine Time and
OEE are a bellwether for performance.
• These metrics, in many ways, become a
measure for best achieving the conversion of
manufacturing investment to margin dollars.
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Technology
• In the past, downtime systems were:
– Manual entry based
• Problem: Inaccurate data for both # of events and durations.
Reporting is labor intensive.
– PLC / HMI based
• Problem: Requires specific code for every machine center.
– Reporting in MS Excel or Access
• Problem: Cumbersome to support.
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Trends in Technology
• Today:
– Solutions are based on Data Historians
– Reporting is Web based
– Independent of the control system
– Build records based on PLC data and operator input.
– Automatically generate summary and Pareto chart
reports to lead planning and maintenance.
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Features
• RtDuet is
– built on Microsoft .net and OSIsoft technology
– simple, easy to use and understand with many built-in shortcuts to free
up time for operations personnel.
– scaleable
– integrated with plant controls in real time
– functionally transparent in plants areas with no control
– easily integrated with corporate databases for business applications and
WEB based reporting.
– integrated with plant NT security structures with user definable roles.
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Features
PI Module Database
Core Module (CM)
[Ace Module]
IIS Web Server
Application Reporting Interface (ARI)
[PI-SDK ActiveX Control]
PI Data
Configuration Toolset (CT)
[PI-SDK Application]
PI Batch Database
External Database
(MSSQL/Oracle/MS Access)
Bidirectional
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Data Transfer Module (DTM)
[Ace Module]
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Benefits
• Large, fast ROI
• Leverage investment made in PI System
• RtDuet provides real tools to improve bottom line results
– efficiency
– production
– maintenance
• RtDuet delivers
– a world class solution well suited for corporate reporting initiatives
– standardized, automated real time downtime and OEE reports
– root cause data for engineering analysis.
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Solution Description
• Provides
Navigation
• ASP.NET
• Links:
– Operator or
Management
Views
– Manual Entry
– Validation
– Reports
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Solution Description
• View events in
real time and
assign causes.
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Solution Description
• Assign Root
Causes
automatically or
when
convienient.
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Solution Description
• Split events.
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Solution Description
• Select multiple
events to add
identical root
cause.
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Solution Description
• Manual entry if
PI data is NOT
available.
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Solution Description
• Validate
automatic or
manual reason
codes.
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Solution Description
• Reports
– Machine
Available Time
vs Utilize Time
– WEB or PDF
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Solution Description
• Reports
– Drill down to
Root Category
– WEB or PDF
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Solution Description
• Reports
– Drill down to
Locations
– WEB or PDF
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Solution Description
• Reports
– Drill down to
Problems
– WEB or PDF
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Solution Description
• Reports
– Drill down to
Causes
– WEB or PDF
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Sample Report
•
OEE Report
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Sample KPIs
•
OEE Report
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ROI – Sample Case
• 3 lines producing 650 d/min
• Asset availability of 85 %
• .85(60 min/hr x 24 hr/day x 365 day/year) =
446760 minutes available to production
• Further understanding unplanned downtime
• Increase asset availability by 1/10th of a %
• 446.7 minutes, 290,394 per line, or 871,182
additional diapers per year.
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1% Availability = $1M
Based on the numbers of a Lean Manufacturing Facility, 1% Increase in Production would translate into 1M/year
100%
Golden Production
100% Availibility
85%
Production Target
650 Diapers/Minute
75%
Current Production
590 Diapers/Minute
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“Minor” Results
Within 3 months, Based on using the information from Duet the following
was realized:
Raw Material Change – based on using the Root Cause
analysis the diaper company was able to realize their glue
type was the cause of multiple downtime events. This
company changed their GLUE type and supplier and
substantially decreased line jams due to glue.
Night Shift Accountability – During night production, many
downtime events were being missed as management
slept…..Duet was able to catch ALL events 24/7, each
requiring reason codes or comments for morning
production reports.
•
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Accurate Production Targets
AMT 95%
Available Machine Time
UMT 85%
Utilized Machine Time
Size 6 Diaper Production/per week
PRODUCTION, ACCOUNTING AND LOGISTICS CAN USE ACTUAL
TARGETS ACCURATELY VS. ESTIMATING TARGETS
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Squeaky Wheel
80
70
60
50
40
30
20
10
0
Oper
Maint
Prod
Raw Mat Quality
Testing
Quality Testing Dept. MAY BE THE “SQUEAKY WHEEL”, BUT NOT THE
BIGGEST PROBLEM
Can accurately assign responsibility and solutions.
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Resource Allocation
90
80
70
60
50
40
30
20
10
0
Bonding Sec Glue Section
HVAC or
Building
Services
Instead of having maintenance focus on small problems,
accurately assign your resources and target the top 10 causes.
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Road Map
• Downtime System for PI for the Mining
Industry
• Evolved to fit needs in Pulp & Paper
Industry
• Evolved further for Nuclear Power Sector
• Now Cross-Industry, Web-Based Out-of
the Box Solution for PI Users written in
.NET.
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Installations Include:
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Wabush Mines
Irving Personal Care
JD Irving
Zinifex
Clorox
Pan Pac
BHP
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Summary
• RtDuet provides real tools to increase
profits by focusing efforts on plant
improvements.
• Thank You
• Questions?
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