1. - Overall Equipment Effectiveness -
DataLyzer® OEE
- Overall Equipment Effectiveness -

2. 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

3. Goal of this presentation
Short introduction of TPM and OEE
Definition of terms
DataLyzer OEE functionality

4. 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

5. 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)

6. TPM
An accurate and practical implementation of TPM, will increase productivity within the total organization, where:
.. 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

7. There are 4 loss types defined in the calculation of OEE:
Scheduled downtime loss
Unscheduled downtime loss
Performance loss
Quality loss

8. OEE Definitions
Also see

9. A lot of definitions are used in industry
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:
See summary in previous slide

10. OEE
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
Downtime loss
Production time

11. OEE
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
Performance
loss
Net operating time

12. OEE
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
Quality
loss
Productive time

13. OEE
OEE = Availability * Performance * Quality Or
OEE = Good products /
Loading time * Ideal machine rate

14. 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

15. 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“.

16. 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

17. 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

18. DataLyzer supports 3 different ways of OEE:
DataLyzer OEE
DataLyzer supports 3 different ways of OEE:
Manual data entry at end of shift
Real time manual entry
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

19. 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

20. 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

21. Manual data entry OEE

22. 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

23. Overview OEE status per productionrun

24. 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

25. 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

26. OEE Reporting in DataLyzer Spectrum

27. 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

28. 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

29. 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

30. Real-time data entry OEE

31. 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

32. Real-time data entry OEE
In status screen downtimes and cause of downtime can be entered. Downtime causes are setup in DataLyzer

33. Breakdown table
Breakdown table shows list of breakdowns
List can be sorted per machine but also of all current machines which are down

34. 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

35. Quality defects and attribute charts

36. 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

37. 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.

38. 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

39. 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

40. 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

41. 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

42. 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