datalyzer® oee - overall equipment effectiveness -
TRANSCRIPT
DataLyzer® OEEDataLyzer® OEE- Overall Equipment - Overall Equipment
Effectiveness - Effectiveness -
• 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
Contents
• Short introduction of TPM and OEE • Definition of terms• DataLyzer OEE functionality
Goal of this presentation
• 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
Contents
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)
Total Productive Maintenance
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
TPM
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
Availability
The availability is the ratio between production time and loading time.
Production time / Loading time
The big losses in downtime loss are :• change over and setup• breakdowns of the machine
OEE
Production time Downtime loss
Performance
The performance ratio is the actual output/ theoretical output or net operating time /. Production time
The 2 big losses in performance loss:• Small stops• Reduced speed
OEE
Net operating time Performanceloss
Quality
The quality ratio is the productive time / net operating time or good products/total products .
The 2 big losses in quality loss are:• Startup rejects• Production rejects
OEE
Productive time Quality loss
OEE = Availability * Performance * Quality
Or
OEE = Good products / Loading time * Ideal machine rate
OEE
• 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
Contents
Time types
Type Name Definition P Production time =
Running time Something is coming out of the equipment, regardless of the amount, speed or quality.
F Failure time = Breakdown time
The machine is not having output due to a machine related technical problem.
W Waiting time = Idle time
The machine is not producing output because it has to wait for something (like a setup, or raw material).Therefore, waiting for a technician during a breakdown is not Failure time, but Waiting time!
L Line restraint time The equipment cannot generate output because it gets no input from the line, or cannot give its output to the line.
U Unscheduled The equipment is scheduled out of the total operations time, for reasons beyond the scope of the production team.
N Not scheduled 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
• 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
Contents
• DataLyzer supports 3 different ways of OEE:1. Manual data entry at end of shift2. Real time manual entry3. 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
DataLyzer OEE
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
• 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
Contents
OEE Reporting in DataLyzer Spectrum
• 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
Contents
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