Improving OverallEquipment Effectiveness(OEE)
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Improving Overall Equipment Effectiveness (OEE)
Evaluating equipment’s ability to perform well at the lowestoverall cost is a real challenge in manufacturing plants. Moredata than ever before is available; capturing and analyzing theright data can be more difficult.
Today’s Agenda1) Introduction to OEE2) Review Ways of Improving OEE3) Customer Benefits
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Manages team of 25channel, and xBU technicalcommunity which supportCP in the market
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⋅ Increase revenue andcommunity within Synergyprogram
Own the control panel Shiftfrom Synergy signage torevenue growth
Applications, Digitalization, and Design
Application Resource Center
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Introduction to OEE
Overall Equipment Effectiveness (OEE) is ameasurement of performance for industrialequipment.
It is based on 3 major components:Availability, Performance and Quality
A P Q OEEX X =
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Availability – A percentagemeasurement based on how muchtime a machine is “available” to runproduction versus a fixed period oftime
Availability =Available timeFixed Period
6 hours8 hour shift
= = 75%
Introduction to OEE
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Performance – A percentagemeasurement based on the actualproduction rate versus a fixedmaximum production rate.
Productivity =Product produced
Max. Product80 units/ hr.
100 units/ hr.= = 80%
Introduction to OEE
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Quality – A percentage measurementbased on good parts versus total partsproduced
Quality = Good producedTotal produced
90 units100 units
= = 90%
Introduction to OEE
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Introduction to OEE
IDA – A simple methodology for drivingimprovement of OEE.It stands for:Information, Decision and Action…drive Results
I D A RX X =
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Plant Floor
Corp HQ
OE
ED
ata
Improved trigger mechanism to record data
Raw Data vs. Knowledge
Barriers
Barriers to Improving OEE
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0 6 8Time (hr.)
Availability
Availability =Available timeFixed Period
6 hours8 hour shift
= = 75%
(How do you improve this)2 Hours of Downtime
Introduction to OEE
Let’s Focus on the Data Trigger
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0 6 8Time (hr.)
AvailabilityWaiting for Maintenance
Repair Time
Operator Idle Time
Does this “Availability” measurement tell the whole story?
Introduction to OEE
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Improving OEE
The First Step in improving “Availability” is by improving“Accountability”.(Identifying Who does What and When)
How Do We Currently Do This?
1) Key Switch 2) Password 3) Paper Log
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The First Step in Improving Availability is by ImprovingAccountability.(Identifying Who does What and When)
How Can We Do This Better?
RFID Key Switch
Improving OEE
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1) Common 22mm pilot device size
2) Communicates to any PLC/DCS via IO-Link
3) Keys are read only
4) Unique shape provides protection against
tampering or duplication
5) Easily attaches to a key ring
6) Unique Hex code ID is assigned at the factory
Improving OEE
RFID Key Switch
RFID Key
04 D7 C8 18 04
Basic Characteristics
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Improving OEE
Key #
04 D7 C8 18 04
04 9A 45 1A 04
C1 F5 C8 18 04
40 D9 C8 18 04
Unique ID
1
2
3
4
• Every key has a uniquehex code ID assignedat the factory
• Similar to a MAC ID toEthernet products
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Improving OEE
• PLC matches ID codefrom the RFID key topreviously storedvalues to identify owner
42 FB 01 1A 04
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Improving OEE
• PLC records date, timeand action every time akey is inserted orremoved
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Improving OEE
ActionWho
04 D7 C8 18 04
C1 F5 C8 18 04
Operator inserts key atstart of shift
Operator removes key andrequests maintenance
Maintenance inserts key andbegins maintenance
Maintenance removes key andcompletes maintenance
What is Recorded in the SystemWhat
Start of Shift
Maint. Req.
Maint. Started
Maint. Completed
When
8:00 am
9:00 am
10:45 am
11:00 am
04 D7 C8 18 04
C1 F5 C8 18 04
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Improving Availability
0 6 8Time (hr.)
AvailabilityWaiting for Maintenance (Sneezy)
Repair Time
Operator (Doc) Idle Time
Now “Availability” measurement tells a more accurate story?
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Improving OEE
• WinCC HMI softwaredisplays recordedevents
WinCC
Solution – Raw Data vs. Knowledge
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Improving OEE
WinCC Performance Monitor Analyzes the Data
Solution – Raw Data vs. Knowledge
• The WinCC Performance Monitor offers reliable analyses on:
• OEE - Overall Equipment Effectiveness
• MTBF - Mean Time Between Failures
• MRT - Mean Repair Time
• and further Key Performance Indicators (KPI).
• The production equipment can be defined individually depending on thespecific plant.
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MindSphere
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MindApps‒Use apps from Siemens, partners or develop own apps‒Gain asset transparency and analytical insights‒Subscription based pricing model
MindSphere‒Open interface for development of customer specific apps‒Various cloud infrastructures: SAP, AtoS, Microsoft
Azure offered as public, private or on-premise (planned)
MindConnect‒Open standards for connectivity, e.g., OPC UA‒Plug & play connection of Siemens and 3rd party products‒Secure and encrypted data communication
Improving OEE
Solution – Raw Data vs. Knowledge
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Field Asset –SIMOCODE
MindConnect Nano
Internet RouterOptional: Proxy
Internet
MindSphere - Siemens Cloudfor Industry
Production / Machine Network
Corporate / Office Network with route to the internet… or direct internet access, e.g. via a DSL modem
PROFINET OPC
PLC/DCS
Improving OEE
Solution – Raw Data vs. Knowledge
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MindSphere
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MindAppsData analytics applications to increase uptime,optimize energy efficiency and enhance cybersecurity.
MindSphere – the cloud-based, open IoT operating system
Siemens OEM Apps App developers End-customers
Siemens products and systems or 3rd party products and systems3rd Party AppsAtos AppsSiemens
MindAppFleet-
manager
Build yourown
Dashboard
OEM App
Analytics
App
Mobile PlantDashboard
ProductionConfirmation
Manufact-uring
Sustainability
AugmentedQuality Mgmt.
Worker
Defect Reporting
…
Solution – Raw Data vs. Knowledge
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Solution – Raw Data vs. Knowledge
Improving OEE
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1) New keys can easily be assigned by a
supervisor
2) Lost keys can be identified if ever used
again
3) Multiple Keys can be assigned to a single
owner
4) Unique shape provides protection against
tampering or duplication
RFID Key Switch
RFID Key
04 D7 C8 18 04
RFID Keys
Benefits
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• Makes it possible to show the weak points of the production and to derivesuitable optimization potential.
• Flexible – Individual calculation of plant specific performance indicators withinSIMATIC WinCC
• Recognizing performance indicators within the content e.g. quality per vendor
• Analyzing of the performance indicators and displaying them as bar- or Gantt –diagram or as a table also using the Web
• Viewing everything at any time – Target–group oriented analysis reports
• Expandable– Adding of performance indicators within existing plants without anyloss of production
Benefits
WinCC & Performance Monitor
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PerformanceManagement APP
Alarm and EventManagement APP
Shift Calendar APP
Energy ManagementPRO APP
SIMATIC SystemDiagnostic APP
MindSphere
Customer focus: System integrators, machine manufacturersFirst industry-specific applications: automotive, F&B, aerospace
Connectivity • Optimized engineering packagesfor integrated configuration
Planned for TIA Portal V15 and following TIA Portal versions
Firs
tDF
FAap
ps
Part
ner
apps
Min
dApp
Benefits
MindSphere – Cloud Based Solution
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Benefits
Siemens Solution is Scalable:
Production Line
Machine
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Benefits
Siemens Solution is Scalable:
Entire Plant
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Benefits
Controls Automation
+
HMI/SCADA
+
Siemens Can Provide a Complete Solution:
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Thank You
John BurnsDF CP
5300 Triangle ParkwayNorcross, GA 30092
Phone: +1 (678) 575-3086
E-mail:[email protected]
www.usa.siemens.com
www.usa.siemens.com/sirius-act
www.usa.siemens.com/wincc
www.usa.siemens.com/mindsphere
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