One of the greatest challenges for manufacturers is knowing what is happening on the shop floor. To solve this, manufacturers use OEE software to collect critical data to provide department heads, supervisors, and operators real-time information about shop-floor activities. This enables them to make faster, more confident production decisions.
But if the objective of implementing production monitoring software is to understand current performance, measure that performance over time, and then improve on it, one must first define performance. To accomplish this, the most common metric for manufacturers to use is Overall Equipment Effectiveness (OEE).
While OEE will help you identify potential losses and understand where your process is falling short, it's so much more than just a performance metric; it's the cornerstone of a continuous improvement strategy.
Overall Equipment Effectiveness, or OEE, measures the efficiency of a machine, taking into consideration the availability, performance, and quality output variables during the run of the machine.
OEE = Availability * Performance * Quality
For the purposes of calculating OEE, the 3 underlying metrics used are as follows:
Availability can also be referred to as Uptime. This is the amount of time the machine is in cycle producing parts compared to the amount of time the machine is scheduled to be in cycle. Any unplanned downtime will result in a lower availability percentage (Blog: Learn how to improve your machine availability). The main factors that hinder machine availability are:
→ Equipment Failures (Breakdowns)
→ Machine Set-Up and Adjustment Time
Performance refers to the speed that parts are produced while the machine is in cycle. It is calculated as the average in-cycle time to produce a part divided by the ideal in-cycle time to produce a part. The more parts produced within a period of time, the higher a machine's performance percentage. Key factors that negatively influence performance include:
→ Machine Idling and Minor Stoppages
→ Reduced Speed of Operation
The quality metric is the percentage of good parts out of total parts produced. Any parts rejected during a run will lower the quality percentage of a machine. Some of the primary reasons for quality reduction include:
→ Process Defects
→ Reduced Yield (from startup to stable production)
With the right information and settings populated in an OEE software, the calculation will be done automatically and populated in pre-built reports and real-time OEE dashboards that can be used for visibility on the shop floor to track production process or for deeper analysis to spot trends, bottlenecks, etc.
Regardless of whether you use manual data collection or OEE data collection software, the following key data points should be collected:
This data is used in calculations for availability, performance, and quality.
Just as many companies within manufacturing industry environments overestimate their equipment performance, so too can unmeasured, legacy, and ad-hoc production processes create a situation where operators and managers assume that one problem is their most significant concern when the real reason may be hidden.
Tracking OEE data can help drill down to the real reason behind each problem. This allows issues to be categorized and prioritized, so that process improvement is conducted on the most pressing problems first and progresses in rank order.
The concept of Six Big Losses is a standard lean tool that categorizes the type of productivity loss. Generally, these six losses include:
Scrap and production rejects result from many factors, including incorrect material, training, or wear and tear.
In many production companies, it takes longer than it should for a machine to go “on-spec,” resulting in wasted material at startup.
By tracking OEE, all these stops can be managed to improve processes and reduce them to the least amount of time possible. In many cases, some of the significant losses can be eliminated. By tracking OEE correctly and accurately, managers can optimize production to reduce losses.
When OEE is properly deployed as a metric, it can reduce equipment costs. Accurate tracking of data can help identify tool wear, out-of-spec parts due to a belt or gear wear, training issues, design problems, and other variables. Managers can use this information to develop an optimized strategy for maintenance, significantly lowering the cost of spare parts and lost tooling.
Capital equipment purchases constitute a significant investment for any production company. With OEE tracking, equipment performance is optimized. This reduces the time required to pay for the investment. This increased production also has the effect of unlocking hidden capacity, also referred to as the “hidden factory.”
With effective OEE tracking, companies may increase equipment uptime to the point that it impacts their entire CAPEX strategy, reducing the amount of equipment that must be purchased to increase production. Not only does this affect the bottom line, but it also means that CAPEX can be spent strategically on other value-added investments or returned to the company in the form of improved cash flow.
Of course, all these benefits cumulatively add to the improvement of production quality. OEE allows companies to optimize production processes by tackling downtime and performance at all runtime phases, including startup, maintenance, shortstops, wear-and-tear, and more. This lowers the occurrence of off-quality material, reducing the cost of lost quality and increasing production.
When OEE metrics are used to capture, categorize, and act upon problems, a clearer picture of the whole factory floor is possible. This holistic approach can be applied at the shift, operator, or machine group level to “see” what is going on that is impacting OEE. Operators can use this visualization to adjust and further improve their performance or that of the machine. Near real-time targets can be set that match the reality on the floor, and changes can be made proactively.
An OEE Report from MachineMetrics.
Manufacturers typically work quickly to identify and solve problems but fail to take the time to understand their root causes. Knowing how to calculate and optimize your OEE can provide answers to both the big picture problem and the details surrounding the problem, and good OEE software helps accomplish this.
The first and most important step to improving OEE is the integration of a machine monitoring system into your shop floor that can automatically collect operational data from both machines and operators. This will provide the production visibility necessary to boost OEE.
MachineMetrics' OEE solution enables manufacturers to not only determine their current OEE but to use it to identify potential problems and understand where processes are falling short. Is it performance, quality, or availability? Does the problem lie with a certain machine, job, shift, or process?
Measuring OEE is much more than just a performance metric; it is the cornerstone of a continuous improvement strategy. Visionary leaders can utilize OEE software to proactively identify issues and promote accountability on the shop floor. Understanding and utilizing OEE can help align the goals of management with real-time plant floor operations. This alignment will encourage all employees to be more proactive, and through this collaborative process, productivity and revenue will increase.
OEE software allows companies to utilize automation and analytics to measure OEE. The software is real-time, web-based, and managed in the cloud. It provides a modular, flexible software solution for discrete manufacturing companies that are on a journey to create a smart factory that fully and accurately tracks their OEE for their production process.
MachineMetrics uses real-time production data straight from the machine control to propogate OEE reports.
By connecting directly to the machine through OEM-embedded capability or by allowing connection over analog or Ethernet connection using devices and sensors located on the edge, real-time OEE software measures variables that involve performance, availability, and quality. It does this through data collection that is sent directly to the analytics engine.
This OEE data collection is then cleansed and standardized by the software. It is then put through advanced analytics platforms to deliver relevant, actionable data for managers and operators to use.
The right OEE data collection software will improve plant performance and drive manufacturing productivity. It will also enable managers to identify the root causes of problems and improve decision-making.
The first step in choosing the right software is to identify your goal. Is it to automate OEE data collection to eliminate the time-consuming process of manually gathering data? Is it to identify the root cause for existing problems or drive manufacturing improvement for all process issues? Whatever the goal, having a clear definition will help you identify the right OEE data collection software.
While all OEE data collection software is broadly used to monitor data, calculate OEE, and help management make accurate decisions to optimize processes, the types of data they can capture and the software's analytical capabilities will vary. Knowing what data you want to capture and what the software can do is critical.
Your ability to improve OEE depends on the insights you have to work with. The ability to quickly analyze in real time goes hand in hand with automated data collection. Gathering data through embedded devices, attached devices, and sensors with high-frequency data and sending it directly to a cloud-based platform for analysis will improve the analysis of OEE data for the entire manufacturing operation.
Once data is analyzed, getting it into the hands of the right people is crucial. Intuitive, customizable automated data collection software lets you build reports and deliver insights to the right people so it can be put into immediate action.
In addition to continuous improvement, operators on the production line can use these insights and even add contextual data to get a machine up and running faster than with manual data collection. OEE values are displayed in easy-to-read formats that empower users.
OEE data can drive continuous improvement throughout the manufacturing operation. Customizable reporting with real-time insights means the data can be put to work immediately for the root cause analysis of problems, to design innovative predictive maintenance strategies, and to reduce costs.
Automated data collection that feeds a robust OEE software with advanced analytics and real-time capabilities will help take OEE to the next level.
The best OEE data collection software should be comprehensive and work across all areas where OEE data is found. This means operating at the physical level with IoT-enabled sensors and devices that have the ability to send the OEE data to the cloud. It also means using strong data processing and real-time analytics to deliver OEE data to users in a form that allows them to act. OEE software must empower action through apps, workflows, and intuitive interfaces.
Must-have features include:
The benefits of OEE tracking are the same when using OEE software. However, the effect is exponentially improved. Manual recording of data can be highly inaccurate, throwing off the overall accuracy of the system. And insights and analytics outside of a software platform are fraught with missed signals and user bias.
OEE software helps manufacturing operations by delivering visualization, insight, reporting, and prescribed actions in real-time. These actions are focused on problem areas and are more accurate and detailed than humans could perform independently. This unbiased, laser-focused analysis and problem detection frees up managers and empowers operators to help create optimized preventive maintenance programs, improve production quality, implement continuous improvement, and more, all with the use of real-time data.
With tablets placed at each machine, operators can add key context to machine data. In the example above, an operator is prompted to log the reason for a downtime event.
If you’re hearing a lot about real-time OEE software these days, there’s a reason for it.
Manufacturers across many different industries - from small shops to fortune 500 companies - are quickly discovering better methods for tracking OEE (Overall Equipment Effectiveness) and identifying automated machine tool monitoring software for tracking the productivity on their shop floors for their entire production process.
How about you? Are there any warning signs in your business that suggest it may be time to integrate real-time OEE software into your operations?
If they haven’t already, it’s only a matter of time before your customers start inquiring about how you track your overall equipment effectiveness. More and more, it’s showing up on project bidding lists as a “must have.” No longer content to get “in the ballpark” reports, potential customers want reliable data that a respected OEE software solution provides. Savvy customers know that the more a modern manufacturer embraces new smart manufacturing and IIoT technologies, the more likely their jobs are to be finished on time. Which brings us to our next indicator...
When jobs are consistently going out the door late, it’s time to zero in and figure out why. No business wants to say goodbye to a customer - especially when it could have been prevented. Real-time OEE software lets you easily track vast amounts of data from your shop floor that you can use to identify hard-to-spot bottlenecks so you can get things back on track.
You’ve probably heard the lean manufacturing mantra, “You can’t manage what you don’t measure.” The same philosophy applies when you make an educated guess about productivity on your shop floor. The whiteboard may suggest one thing, but real-time machine monitoring and manufacturing OEE software often reveals a truer picture of what your uptime actually is. When jobs and schedules are actually held up against expected cycle times, the results can be eye-opening.
Real-time machine data is highly accurate and does not lie. It is not subject to the bias and inaccuracies of manually tracking your production, leading to decisions that are based on fact.
Improving company culture starts with communication strategies and tools that recognize and reinforce the most important outcomes your employees create for your business. A real-time OEE system gives you an opportunity to transform your shop floor into a laboratory that generates accurate data that you can use to create clear targets for tracking individual and team performance. Not only does it put accountability into their hands in a fair and practical way, it sends a message you are interested in a successful, long-term relationship.
Ouch. When your business is leaking money, it’s important to figure out why - and fast. Often, the source of the problem can be traced to inefficient manufacturing processes. The challenge? Finding them. That’s where real-time OEE software can play a key role. The main culprit that machine monitoring can help you attack is unplanned downtime. OEE software gives you access to accurate information that allows you to view your entire manufacturing process and spot potential profit killers.
To understand how OEE software addresses many of the issues associated with manually tracking production data and key metrics, we can examine some brief examples:
One example may be identifying the top causes of downtime. Tracking OEE without software can deliver improvement. But there is a chance that the lack of data quality may lead to a manufacturer addressing the third leading cause of downtime, rather than the most egregious downtime reason. With OEE software, you can ensure that the number one cause is easily identifiable. This shortens time to improvement and delivers greater value, as you can quickly move on to the next opportunity.
The MachineMetrics Downtime Pareto chart identifies the top reasons for downtime, helping you to prioritize the areas for improvement.
Because OEE software relies on sensors and edge devices, categorizing the type of loss is both more accurate and highly actionable. For example, with MachineMetrics captures real-time data is captured at the edge and can be used to enable workflows based on certain thresholds, alarms, parameters, or manual triggers to enable communication and process optimization. This helps ensure that maintenance, quality, tooling, and other issues are resolved as fast as possible, or even prevented altogether, ensuring as little downtime as possible.
OEE software is real-time and cloud-based. Coupled with advanced analytics, this means that costs are lower with increased uptime, and capacity is optimized. For example, if a company is able to optimize its equipment utilization by closely monitoring OEE and acting on opportunity areas, it may prevent expensive capital expenditures associated with purchasing new equipment in order to hit a given production goal.
Can your company identify with any of these production red flags? Are you having difficulty getting visibility and control of the shop floor? Is your data inaccurate, delayed, or non-existent? If so, MachineMetrics can help.
MachineMetrics can deliver a solution using real-time OEE software that will give your organization the most accurate production visibility in real-time, creating a smart factory environment to optimize OEE. To learn more about our OEE solution, book a demo today.
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