Engineering - Design - System Integration

METRICS

OEE

Versa Tech provides the design, programming, installation and commissioning of Rockwell FactoryTalk Metrics to provide an Overall Equipment Effectiveness (OEE) Data Collection and Monitoring System.

Decrease Cost

Increase Capacity

Defer Capital Expenditure

Overall Equipment Effectiveness (OEE) Data Collection and Monitoring System.

Versa Tech implements FactoryTalk Metrics on a single Workcell, a process line or an entire facility.

FactoryTalk Metrics implementations typical investment paybacks are weeks or months (not years). However, business management is often skeptical until they see the bottom line results of OEE data providing the solutions to the root causes of production losses.

Inquire about Versa Tech trial installations to solve any business management investment reluctance.

FactoryTalk Metrics software monitors plant-floor equipment providing accurate, real-time, information on equipment production and performance. This data is the basis for understanding the real causes of inefficiency, waste, lost capacity, and higher costs.

FactoryTalk Metrics provides the data to define the appropriate action for process improvement initiatives, resulting in reduced downtime, decreased cycle time, and increased overall production.

FactoryTalk Metrics requires just a few data points from the control system for calculating Overall Equipment Efficiency (OEE) and other KPIs.

The OEE FactoryTalk Metrics Data Collection and Monitoring System function and purpose is to provide:

Monitoring, Tracking and Historizing of the plant floor production equipment to determine equipment and labor effectiveness

Provide information of the root-causes of loss performance and downtime

Provide information to make the comparison of effectiveness based on production line, material and operators

Manual data entry through HMIs

Automatic data collection through PLC

Visualization of performance results through Plant Floor displays

Reporting real-time and historical trending information to plant computers.

Understanding OEE

Overall Equipment Effectiveness (OEE) is the accepted standard for measuring manufacturing productivity to reduce costs and increase profits.

For manufacturers, the fastest method to reduced costs with minimal additional investment is to utilize existing production equipment more effectively.

The improvement in Overall Equipment Effectiveness (OEE) is accomplished by:

Increased capacity
- More product, revenue, and profit in the same amount of time
Decreased manufacturing costs
- Less overtime, reduced labor costs, lower per-unit costs
Deferred capital expenditures
- Make your current equipment more productive

OEE is the single best metric for identifying:

Production losses
Bench marking progress
Improving the productivity by eliminating waste
Determine where to make improvements & capital investments
Improve scheduling, training, equipment PMs

This is accomplished through accurate measuring and reporting of real plant-floor activity, allowing you to make focused improvements that will result in higher equipment efficiencies.

OEE = Availability X Performance X Quality

Availability = Run Time / Planned Production Time

Availability takes into account all events that stop planned production long enough where it makes sense to track a reason for being down (typically several minutes).

Run Time = Planned Production Time − Stop Time

Ideal 90%, Typical 80%

Performance = (Ideal Cycle Time × Total Count) / Run Time

Performance takes into account anything that causes the manufacturing process to run at less than the maximum possible speed when it is running (including both Slow Cycles and Small Stops).

Ideal 95%, Typical 80%

Quality = Good Count / Total Count

Quality is similar to First Pass Yield, in that it defines Good Parts as parts that successfully pass through the manufacturing process the first time without needing any rework.

Ideal 99%, Normal 95%

An OEE score of 100% means you are manufacturing only Good Parts, as fast as possible, with no Stop Time. In the language of OEE that means 100% Quality (only Good Parts), 100% Performance (as fast as possible), and 100% Availability (no Stop Time).

World Class manufacturing plants achieve 85%. (90%x90%x99%)

Prior to implementing OEE data collection and analysis a typical plant will be operating at OEE of 60%. (80%x80%x95%)

Management typically believes their plant is running at much higher OEE until the true data is collected and analyzed.

Although OEE can be collected and analyzed manually, automatic data collection is very cost effective, more accurate and more timely reporting.

Versa Tech has implemented FactoryTalk Metrics installations which have had a capital payback within 2 months.