In our last post we described the OEE framework and how OEE is calculated from the recorded downtime and yield values. In this post we want to show how Provideam provides a powerful way of storing, analysing and reporting on this recorded data.

There are three main aspects to Provideam

•  A database for efficient data storage
• Business logic for analysing the raw data
• An intranet webased user interface for developing customisable reports

 

Storing your data in a Provideam, enterprise-class database based solution has many advantages over a spreadsheet or paper based reporting system;

• the data is stored securely
• the data is available to multiple simultaneous users
• the data is easily analysed over different time periods
• the data is easily cross-referenced to pick up on issues related to specific parts, tools etc.
• business rules are protected and not liable to user error
• reports are consistent and can be delivered automatically by email

 

Provideam includes a Manual Entry user interface to facilitate the collection of downtime and yield data as described above. To get started you simply need to;

1. install Provideam
2. create a machine profile which describes the downtime modes and yield values
3. define the shift cycle which defines the start and end of each shift

 

We won't go in to too much detail about configuring machines here save to say it's easy and quick. Below are a few screen shots to give you the idea;
 

Fig: Filler Machine Properties

 In the figure above you will see the Filler Machine properties. The properties indicate that the DataSource is ‘Manual Entry’, that we will use a 2 Shift Cycle and that we will not display advanced items such as Lot, Part, Tool etc. If the DataSource was ‘automatic’ it would indicate that data is being collected automatically from the machine.

 

Fig: Filler Machine Downtime Modes

Above you will see the list of the Downtime Modes which we have created and can be assigned by the Operator to the Filler Machine.

Fig: Filler Machine Yield Types

In the figure above we show the types of Yield Count we have defined for the Filler Machine.

 

Fig: Filler Machine Part-Standard Time Relationships

The above figure shows that the Standard Time to produce 1 bottle on the Filler is 3 seconds (ie .05mins). In a more complex example with several Parts, we would have a record here with the Standard Time for each Part.

 

We are now ready to enter data.

1. Select the Manual Entry Page and click on the Add New Shift to create a Shift for the Filler Machine.

Fig: New Filler Machine Shift

2. Now add Planned and Unplanned Downtime

Fig: New Filler Shift – Add Downtime

3. Now add Yield Count Values

Fig: New Filler Shift – Add Yields

Note: You may add the yield values in one go, as I have done here, or you can distribute the yield over the shift hour by hour. If you enter the yield values hour by hour then you will be able to report on OEE hour by hour.

 

The data has now been entered for this shift and we can look at the results…

Fig: New ShiftOEE Analysis

Note: The top table shows the Good Parts, Defect Parts, OEE, Availability, Performance and Quality – same as in our example in the previous post. The Pie Chart shows OEE Time as 76.39%. This should not be confused with OEE. What this means is that OEE Time represented 76.39% of the Shift as a whole (ie 12hours) – you will notice that Planned DT is included in the Pie Chart. If we redrew the Pie Chart with out Planned DT, then our OEE Time % would be the same as our OEE %. In the sample reports created below we have excluded Planned DT from the Pie.

 

Report Examples:

• Example 1: OEE Loss Pie and Table for OEE Level 1(ie losses grouped by Availability, Performance, Quality) – (NewShiftReportLvl1.pdf)
   
• Example 2: OEE Loss PIE and Table for OEE Level 3(ie lowest level loss descriptions) – (NewShiftReportLvl3.pdf)
   
• Example 3: Production Report showing various functions calculated for 3 Machines – (NewShiftProdReport.pdf).

 

Example 3 shows a combination of 'Automatic' and 'Manual Entry' machines. The data for AssemblyMC1 and AssemblyMC2 is captured automatically. The purpose of the example is simply to show that it is possible to have a standardised method of reporting across all areas of the plant.

 

That concludes this post. In our next post we will show a more complex example with several Part each with its own Standard Time.

Provideam Tips

 

OEE Loss (by Object) Shift Report with Pie Chart

A standard Provideam Loss Report might appear like the example in figure 1 below.

Fig. 1 OEE Loss by Object Report

 

In this report we see a breakdown of the losses for AssemblyMC1 for the Day Shift on the 2nd of October. The losses are displayed both in graphical

and tabular format. The upper table shows a list of the losses sorted in descending order of magnitude of the Time function. The lower table shows a

selected list of functions calculated over the shift. These ‘overall’ functions help to put the loss figures in context.

 

To help us get a perspective on the actually losses we have included the OEE Time in this report (the green pie segment). This is the total time

that the machine was running at its optimum rate. It is a feature of Provideam that you can specify whether to include or exclude categories of loss

on your reports.

 

To create a report like that shown in figure 1 above, follow these steps;

Step 1: Click on the ‘New Report’ icon
Step 2: Select the OEE Loss (Group by Object) option

 

Fig. 2 OEE Loss by Object Report – New OEE Loss Report

Step 3: Click Next to move on to the Area/Machine (Object 1) selection.
Step 4: Select AssemblyMC1 from the list of available Machine items.

 

Fig. 3 OEE Loss by Object Report – Select Object

Step 5: Click Next to move on to name the Object.

By default the Report Wizard enters the Object Description shown below. You may edit this if you wish.

 

Fig. 4 OEE Loss by Object Report – Edit Object Description

Step 6: Click Next to move on to on to the Loss selection.
Step 7: Choose Level 1 Loss and select All from the list of available Level 1 Loss items. This option results in all time, from OEE Time to Planned

Downtime, being included in the Loss Report.
Step 8: Check Show for Level 3 Desc. This results in a breakdown by Level 3 Description on the final report.

 

Fig. 5 OEE Loss by Object Report – Select Loss

Step 9: Click Next to move on to Functions selection.
Step 10: Select Time from the list of available Loss Function items.
Step 11: Select PlannedOpT, UpTime, Downtime, Good Parts and Defect Parts from the list of available Production Function items.
Step 12: Use the Up and Down buttons to order the Functions. They will appear in the final report in the order  you set here.
Step 13: Check the Show Grand Totals checkbox.

 

Fig. 6 OEE Loss by Object Report – Select Functions

Step 14: Click Next to move on to Period selection.
Step 15: Select the Shift period option.

 

Fig. 7 OEE Loss by Object Report – Select Period

Step 16: Click Next to move on to the final screen in the Report Wizard.
Step 17: Select the Pie Chart Graph option.
Step 18: Check the Show Graph option.
Step 19: Click Run Report to run this Report.

You may save the report definition as a Report Template at this stage. Report Templates can be shared with other users and also scheduled for

automatic delivery by email.

 

Fig. 8 OEE Loss by Object Report – Select Graph Style

Step 20: Select a Date and Shift.

 

Fig. 9 OEE Loss by Object Report – Select Report Period Parameters

Step 21: Click Run Report to generate a report preview.

 

Fig. 10 OEE Loss by Object Report – Preview Shift Report
 

Provideam Tips OEE, OEE and Lean Manufacturing, OEE Loss, Overall Equipment Effectiveness