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Transcript of SIMATIC IT OEE
siemens.com/simatic-it
SIMATIC IT OEE
© Siemens AG 2013 All rights reserved. siemens.com/answers
The Four Operations of ISA 95The Four Operations of ISA-95
SIMATIC IT OEE-DTM addresses Production and Quality Management of ISA-95Q y g
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© Siemens AG 2013 All rights reserved.
Page 2 Author / Department
S������ T��� MES � CMMS
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ISA 95 Standard Operation Pillars in detailISA-95 Standard Operation Pillars in detail
P d ti O ti Pill Q lit O ti PillProduction Operation Pillar Quality Operation Pillar
Production Production
© Siemens AG 2013 All rights reserved.
Page 3 Author / Department
Key questions for manufacturersKey questions for manufacturers
High Performance, high Quality, high Availability…
…the everyday targets in the plant……need to improve maintenance and operational performances…
g , g y, g y
Which is the actual performance against my performance targets?How effectively is the organization using its assets?Why my capacity is idle or non-productive?Why my capacity is idle or non productive?Are resources being used efficiently for the products currently produced? What is the economic impact of the inefficiency?How much revenue has been lost due to the operationalHow much revenue has been lost due to the operational inefficiencies?Why two teams, that appear to be equal, produce products that are so different?Is your factory fully utilized?Is your factory fully utilized?Does your process create waste when stopped?
© Siemens AG 2013 All rights reserved.
Page 4 Author / Department
All necessary data must be available to make informed decisions
The “Six Big Losses”The “Six Big Losses”
In manufacturing plants the most common causes of efficiency loss have beenIn manufacturing plants the most common causes of efficiency loss have been identified and
classified as the “Six Big Losses”
Six Big Losses Category Comment
Breakdowns
Setup / Adjustments
Downtime Loss
Downtime Loss
Difference between Breakdown and Small Stop
Includes tool changeovers
Small Stops / Idling
Reduced Speed
Speed Loss
Speed Loss
Only stops under (5) minutes and no maintenance
Process not running at its theoretical speed
Startup Rejects
Production Rejects
Quality Loss
Quality Loss
Scraps in warm-up, startup or other early production
Scraps during steady-state production
© Siemens AG 2013 All rights reserved.
Page 5 Author / Department
OEE CalculationOEE-Calculation
OEE is a total measure of performance that relates the availability of process to
OEE controls and reduces the “Six Big Losses”
OEE is a total measure of performance that relates the availability of process to productivity and quality
OEE-Category OEE-CalculationStandby
D ti L
Not part of OEE calculation
A il bilit i th ti f ti ti t l d d ti tiDowntime Loss Availability: is the ratio of operating time to planned production time.
100% availability means the process has been running with no recorded stops
Speed Loss Performance: is the ratio of ideal cycle time to actual cycle time, or alternatively the ratio of actual run rate to ideal run rate.
100% performance means the process has been consistently running at its theoretical maximum speed
Quality Loss
theoretical maximum speed
Quality: is the ratio of good parts to total parts.
100% quality means there have been no reject or failure in parts
© Siemens AG 2013 All rights reserved.
Page 6 Author / Department
OEE = Availability * Performance * Quality
World Class OEEWorld Class OEE
A erage of OEE rate in man fact ring plants is 60%
World Class OEE is considered to be 85% or more
Average of OEE rate in manufacturing plants is 60%
OEE FACTOR World Class
Six Sigma is not enough!
99 % in Quality
Availability 90,0 %
Performance 95,0 %99 % in Quality
doesn’t mean
OEE >= 85% !
Quality 99,0 %
OVERALL OEE 84,6 %
Big Room for Improvements
© Siemens AG 2013 All rights reserved.
Page 7 Author / Department
Engineering an OEE DTM SolutionEngineering an OEE-DTM Solution
D l f i ffi i i d d i l i
Plant model Equipment hierarchy is shared with SIMATIC IT Production
Deployment of equipment efficiencies and downtime management solution
Time model Define general time categories as a basis for Key Performance
Plant model definition
Equipment hierarchy is shared with SIMATIC IT Production Modeler
configuration Indicators (KPI) calculation
Reason tree configuration
Define all the possible equipment status conditions (failures, stops states reasons )configuration stops, states, reasons, …)
Data collection configuration Configure data collection in SIMATIC IT Historian
KPI configuration Customize and personalize KPI algorithms
g
© Siemens AG 2013 All rights reserved.
Page 8 Author / Department
SIMATIC IT for OEESIMATIC IT for OEE
SIMATIC IT OEE-DTM is a product option of SIMATIC IT Historian, and it is wholly and seamlessly integrated within the entire MES solution
SIMATIC IT for OEE, through integration with the entire SIMATIC IT environment, allows:
• the calculation of all “standard” and “custom” KPIs
• to fully support the Downtime Management
• to perform active and corrective actions to react to efficiency decreases
• to improve economic Return on Investments (ROI)
• to maximize the plant performance
© Siemens AG 2013 All rights reserved.
Page 9 Author / Department
KPI EvaluationsKPI Evaluations
SIMATIC IT OEE-DTM manages efficiency-related and downtime-related KPIsSIMATIC IT OEE DTM manages efficiency related and downtime related KPIs
Pre-defined standard KPIs algorithms:Availability rate, Performance rate, Quality rate, OEE, MTTA, MTBF, MTTR, MTBA, and more…
Possibility to create new custom KPIs algorithms,combining the existing ones or implementing brand new ones
All th i di t d b SIMATIC IT OEE DTM il bl ithAll these indicators, managed by SIMATIC IT OEE-DTM, are available either :
for executives (who, having an extended vision of the overall plant, manage indicators and charts)
for operators (who mainly monitor run-time views, customizing downtime parameters, and have a restricted view of a specific nit)
© Siemens AG 2013 All rights reserved.
Page 10 Author / Department
specific unit)
Downtime Management and AnalysisDowntime Management and Analysis
Downtime Management:detailed information about equipment states can be displayed updated and filteredcan be displayed, updated, and filtered by equipment, status, product, or any other context data
Downtime Analysis:enables exploring the causes that have generated a production breakdown
© Siemens AG 2013 All rights reserved.
Page 11 Author / Department
generated a production breakdown
Runtime AnalysisRuntime Analysis
SIMATIC IT f OEE id b f d fi d hi ifi ll b ilt iSIMATIC IT for OEE provides a number of predefined graphics screens specifically built in
order to provide out-of-the-box analysis OEE-related KPIs and equipment downtimes
P d fi d hi bj t il bl t b ild dditi l hiPre-defined graphic objects are available to build additional graphics
SIMATIC IT Client Application Builder provides the engineering and run-time platform forSIMATIC IT Client Application Builder provides the engineering and run-time platform for the user interface, since the user interface is built on top of standard technology (namely .Netfrom Microsoft) a wide range of third-party graphic objects can be embedded in any GUI interface for OEE analysis
© Siemens AG 2013 All rights reserved.
Page 12 Author / Department
interface for OEE analysis
Easy and flexible engineering phasesEasy and flexible engineering phases
Time Model:through its graphical representation, it provides an easy way to create the complex model
Reason Tree:it defines in details the hierarchy of all the possible machine states within the defined time categories for individual or for groups of equipments
Shift Calendar (SHC) Management:strong integration between equipments and calendars are defined in the SHC component
© Siemens AG 2013 All rights reserved.
Page 13 Author / Department
Comprehensive and detailed analysis phasesComprehensive and detailed analysis phases
Production Counter Analysis:Production Counter Analysis:
Produced units, scraps, reworked units and any other production counter can be displayed and summarized, according to the different grouping criteria
Current production can be compared with theoretical productionproduction
Reporting:Reporting:
SIMATIC IT for OEE makes use of SIMATIC IT Report Manager in order to provide flexible and effective performance reporting (customized according to the user needs)
Reports can be launched directly from the web
© Siemens AG 2013 All rights reserved.
Page 14 Author / Department
Focus on what’s new in SIMATIC IT OEE v1 2 SP2Focus on what’s new in SIMATIC IT OEE v1.2 SP2
Planned / Induced Downtime Management
MES Context Support
On Value Change Design Speed Acquisition
Web Client integrated in SIMATIC IT CAB PortalWeb Client integrated in SIMATIC IT CAB Portal
GUI Enhancements
Predefined Reports
Documentation enhancements
Note: SIMATIC IT OEE V1.2 SP2 is compatible with SIMATIC IT Production Suite V6.3 SP2
© Siemens AG 2013 All rights reserved.
Page 15 Author / Department
Planned / Induced DowntimePlanned / Induced Downtime
Two special types of downtime records defined either through a dedicated OEETwo special types of downtime records, defined either through a dedicated OEE Web Client page, or programmatically through COM or GSI methods:
Pl d D tiPlanned Downtimes• which cause OEE to disregard the status information retrieved from the field
for the specified time span, are used when an equipment have predefined planned time where it is off-line.
Induced Downtimes• used to model a ”bottleneck“ situation, where the machine state of a piece of
equipment depends on the state of another piece of equipment. They are q p p p q p yused to put in Downtime status an equipment on real-time.
© Siemens AG 2013 All rights reserved.
Page 16 Author / Department
Planned DowntimePlanned Downtime
A Pl d D ti i i d f d ti fi d t i th f tA Planned Downtime is a period of downtime configured to occur in the future.
Th f ll i t d fi l d d tiThe following parameters define a planned downtime:
• A start-time and an end-time (b th i th f t )(both in the future)
• A machine state
• The piece(s) of equipment involved
© Siemens AG 2013 All rights reserved.
Page 17 Author / Department
Induced DowntimeInduced Downtime
An Ind ced Do ntime is a period of do ntime hich as ca sed b anotherAn Induced Downtime is a period of downtime which was caused by another downtime occurring on a different piece of equipment.
A start time set when the record is opened
An end time set when the record is closedAn end time set when the record is closed
A machine state
The piece(s) of equipment involved
© Siemens AG 2013 All rights reserved.
Page 18 Author / Department
MES Context SupportMES Context Support
The following predefined MES Contexts are managed for downtimeThe following predefined MES Contexts are managed for downtime, counter and design speed records:
GroupNameUserNameLotIDO d IDOrderIDBatchIDShiftUserCommentUserComment
The user can set the context values either:The user can set the context values either:manually (by a programmatic interface)
automatically (by either a screen or a Production Modeler rule)
© Siemens AG 2013 All rights reserved.
Page 19 Author / Department
On Value Change Design Speed AcquisitionAcquisition
I OEE V1 2 SP1 th i th ibilit t i d i d l d tIn OEE V1.2.SP1 there is the possibility to acquire design speed values on data change: the user must define two RTDS points (one to trigger the design speed reading and one to retrieve the design speed value)
Now, the user can easily define all the parameters of design speed acquisition, beyond product id and context acquisitionq
© Siemens AG 2013 All rights reserved.
Page 20 Author / Department
Web Client integrated in SIMATIC IT CAB Portal
The following predefined pages are provided fully-integrated in SIMATIC IT CAB
Web Client integrated in SIMATIC IT CAB Portal
g p p g p y gPortal:
• Counters Graphic
• Counters Grouped
• KPI Viewer
C Vi• Counters Viewer
• Design Speed Viewer
• DTM Viewere e
• Gantt Viewer
• Runtime Operator Panel
• Equipment Comparison
• Context Management
Pl d D ti
© Siemens AG 2013 All rights reserved.
Page 21 Author / Department
• Planned Downtime
Predefined ReportsPredefined Reports
Th f ll i t id dThe following reports are provided:
Actual &Target
Downtime
DTM Detail
Availability details
Counter values
DTM values
© Siemens AG 2013 All rights reserved.
Page 23 Author / Department
Documentation enhancementsDocumentation enhancements
This version includes the following new documents:
OEE Developer Guide: a comprehensive guide on how to use OEE programmatic interfaces to develop custom applicationsp g p g p pp
OEE Installation Manual: a dedicated installation manual for SIMATIC IT OEE
OEE Web Client Documentation: new contextual documentation accessible directly from OEE Web Client pages
Additionally, the following existing documents have been substantially updated:OEE Concept GuideOEE Concept Guide
OEE Functional Overview
© Siemens AG 2013 All rights reserved.
Page 24 Author / Department
SIMATIC IT OEE DTM benefitsSIMATIC IT OEE-DTM benefits
Through integration with SIMATIC IT Production Modeler:
SIMATIC IT OEE-DTMkey benefits:
Reducing efforts to collect real time production Increase acquisition performances using high speed acquisition rules
Customization of the application through the user-
Reducing efforts to collect real-time production information
Preventing unscheduled downtimes
exits capabilities, inside the Production Modeler (PM) rules
Speeding-up acquisition performances by buffering
Improving of data synchronization and safety with data recovery system
Maximization of production equipment utilizationp g p q p y g
mechanisms
Improvement of the acquired data contextualization
Reducing maintenance costs by optimizing planning activities
Improving assessment and business process performance
Definition of high-level contexts
performance
Easy Import / Export configuration data from Excel worksheets
O ti i i d t lit di
© Siemens AG 2013 All rights reserved.
Page 25 Author / Department
Optimizing product quality grading process
Counters GraphicCounters Graphic
Counters Graphic displays the value of one or more counters (sum) associated toCounters Graphic displays the value of one or more counters (sum) associated to a piece of equipment in a trend graph
Additionally, it is also possible
to display the equipment unit’s
design speed in the trend,
if it was configured during the
engineering phaseengineering phase.
© Siemens AG 2013 All rights reserved.
Page 26 Author / Department
Counters GroupedCounters Grouped
Counters Grouped displays counter values in tabular form grouped according toCounters Grouped displays counter values in tabular form grouped according touser-defined filters on contexts
Such filters can be set ifcounter values where acquired withcontexts during the engineeringcontexts during the engineeringphase.
© Siemens AG 2013 All rights reserved.
Page 27 Author / Department
KPI ViewerKPI Viewer
KPI Viewer displays KPIs associated to a particular piece of equipment using one of the following graphs:
• Bargraph
• Trend
• Stacked bargraph
• Pareto chart
© Siemens AG 2013 All rights reserved.
Page 28 Author / Department
Counters ViewerCounters Viewer
C t Vi di l t d i t b l fCounters Viewer displays counter records in tabular form
© Siemens AG 2013 All rights reserved.
Page 29 Author / Department
Design Speed ViewerDesign Speed Viewer
Design Speed Viewer displays design speed records in tabular form and it alsoDesign Speed Viewer displays design speed records in tabular form, and it also gives the user the possibility to edit them and export them to a CSV file
© Siemens AG 2013 All rights reserved.
Page 30 Author / Department
DTM ViewerDTM Viewer
DTM Viewer let the user to visualize and manage the DownTime recordsDTM Viewer let the user to visualize and manage the DownTime records
© Siemens AG 2013 All rights reserved.
Page 31 Author / Department
Gantt ViewerGantt Viewer
Gantt Viewer displays downtime records related to one or more pieces ofGantt Viewer displays downtime records related to one or more pieces of equipment in a Gantt chart
The user can perform the following actions:Filter data by
equipmentequipmentcontexttime interval
Zoom in and out the chart
Export and print data
© Siemens AG 2013 All rights reserved.
Page 32 Author / Department
Runtime Operator PanelRuntime Operator Panel
Runtime Operator Panel gives a general overview on the efficiency of aRuntime Operator Panel gives a general overview on the efficiency of a piece of equipment
Two types of trend charts can be displayed:
Production ChartProduction Chartto view the values of all the counters associated to the piece of equipment
OEE Chartto view all OEE indicators associated to the piece of equipment.
© Siemens AG 2013 All rights reserved.
Page 33 Author / Department
Equipment ComparisonEquipment Comparison
E i t C i i th th t it t tEquipment Comparison gives the user the opportunity to compare two or more pieces of equipment
For each piece of equipment, the following KPIs are displayed (if available):
OEEAvailabilityPerformancePerformance QualityCurrent counter values
© Siemens AG 2013 All rights reserved.
Page 34 Author / Department
Note: This page provides only real-time data and can be configured to refresh itself automatically or manually.
Context ManagementContext Management
Context Management can be used to set the current values for one or more contexts which were defined during the engineering phase
By doing so, it is possible to modify contextualization of:
design speed, counter downtime recordsdowntime records
© Siemens AG 2013 All rights reserved.
Page 35 Author / Department
Planned DowntimePlanned Downtime
Pl d D ti ll th t t Pl d D Ti fPlanned Downtime allows the user to set a Planned DownTime for one or more equipment
© Siemens AG 2013 All rights reserved.
Page 36 Author / Department
ContactsContacts
For further information please contact:
siemens.com/answers
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