Production Unit Properties – Production Metrics
Downtime | Efficiency | Production | Waste | Non-Productive
Production Metrics are assigned and configured only for Unit Types of Production Equipment. These units are directly involved in production, and are used to track production amounts. Production, downtime, and waste rates are used on a unit-by-unit basis to report on production values versus specifications, to trigger alarms based on specification limits, and to report on long term production conformance. Also, different plants—or different operations within a plant—may choose to use custom OEE calculations using variables in the Plant Model rather than built-in OEE functionality, but have the results of the calculations still shown in standard reports. This choice is available in the Efficiency tab.
For more information, also see: Specifications for Production Metrics Alarming and Overall Equipment Effectiveness (OEE).
In order to calculate OEE, you must configure Downtime, Production, and Waste for the production unit.
To configure the Downtime metrics for a Production Unit:
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On the Production Metrics tab, click the Downtime tab.
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From the Unavailable Downtime Category drop-down list, select a category. These categories are defined in the Reason Tree (Global Configuration), and allow a group of reasons to be specified that define scheduled downtime. The category here is used in the OEE calculation to define total runtime, etc.
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From the External Downtime Category drop-down list, select an External Downtime Category that is defined in the Reason Tree configuration to allow a group of reasons to be specified that external source downtime. This is then used in the OEE calculation to define total runtime, etc.
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Select the Unavailable Downtime Percent. Click the
button to select the Specification Variable that contains the specifications. The Downtime Percent Specification is used to trigger a specification limit alarm when a certain percentage of downtime is exceeded for the interval defined below.
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Select the Enable Downtime Alarms check box if you want to trigger downtime alarms. If this option is selected, an alarm is triggered whenever downtime exceeds the specification limit defined by the specification variable selected in the previous step. To view these alarms on the Alarm display, you must select this unit on the Unit tab when configuring the Alarm display. For more information, see the topic, Configuring an Alarm View Display.
Alarms are not tied to the OEE calculation.
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In the Calculation Interval box, enter the number of minutes between calculations.
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In the Calculation Window box, enter a number of minutes to define the time period over which calculated values will be averaged.
For example, if the Calculation Interval is 5 minutes and the Calculation Window is 1440 then the Total Percentage Downtime calculation will be calculated every 5 minutes over the 1440 minute interval. These values are then compared to the Downtime Percent Specification to determine if the acceptable amount of downtime for each interval has been exceeded.
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Click Save when finished.
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Click the Close
button to close the Unit Properties Configuration dialog box.
To configure the Efficiency Metrics for a Production Unit
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On the Production Metrics tab, click the Efficiency tab.
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Do one of the following:
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Select Use Standard Efficiency Calculation if you want to use Plant Applications' built-in OEE functionality.
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Select Use Efficiency Calculation Variable if you have configured a variable that calculates OEE. Click the Browse button to search for the variable.
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Select the Efficiency Percent Specification. Click the
button to select the Central Specification Variable that contains the specifications. The Efficiency Percent Specification is used to set a specification limit to alarm against when a certain percentage of Efficiency is lower than the limit for the interval.
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Select the Enable Efficiency Alarms option if you want to trigger Efficiency alarms. If this option is selected, an alarm will be triggered whenever the Efficiency exceeds the specification limit defined by the Specification Variable you selected in step 5. To view these alarms on the Alarm display, you must select this unit on the Unit tab when configuring the Alarm display. For more information, see the topic, Configuring an Alarm View Display.
Alarms are not tied to the OEE calculation.
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In the Calculation Interval box, type the number of minutes that will determine how often the calculation is triggered.
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In the Calculation Window box, type the number of minutes that defines the time period over which values will be averaged.
Enable Efficiency Alarms turns on the calculation of Percentage Efficiency compared to the Efficiency Percent Specification. If the Calculation Interval is 5 minutes and the Calculation Window is 1440 then the Total Percentage Efficiency calculation will be calculated every 5 minutes over the 1440 minute interval. These values will get compared to the Efficiency Percent Specification to determine if the acceptable amount of efficiency has been to low for each interval.
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Click Save when finished.
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Click the Close
button close the Unit Properties Configuration dialog box when completed.
To configure the Production Metrics for a Production Unit
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On the Production Metrics tab, click the Production tab.
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Do one of the following:
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Select Production is Accumulated From Event Dimensions: Standard Production Total is the total of Dimension X for all events with a Status defined as a Production Counting Status that falls within the time frame of the Schedule Process Orders Start and End Time. Dimension X is the Final_Dimension_X value taken from the Event_Details table for these events. The Process Order times on a Schedule are takend from the Production_Plan_Start Production_Plan_Start tables Start_Time and End_Time. The Production Statuses that are defined as ’r;Is Production’ comes from the Production_Status table and the Count_For_Production table. So if the event has a status that is set for Count_For_Production and has a Final_Dimension_X value, then it will count towards production.
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Select Production is Accumulated From a Variable:Production Total from a Variable uses a specific Variable's value and totals it for the time frame of the Schedule Displays Start and End Time for each Process Order. The Process Order times on a Schedule are taken from the Production_Plan_Start tables Start_Time and End_Time. If using a customized Accumulation From a Variable then select the Browse button
to select the variable.
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From Performance Downtime Category, choose the downtime category. These categories are defined in the Reason Tree, and allow a group of reasons to be specified that define scheduled downtime. The category here is used in the OEE calculation to define total runtime, etc.
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Select the Production Rate Specification. Click the Browse button
to select the Central Specification Variable that contains the specification. The Production Rate Percent Specification is used to set a specification limit to alarm against when a certain percentage of Production Rate is lower than the limit for the interval.
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From the Production Rate Time Units drop-down list, choose Day, Hour, Minute, or Second.
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Select the Enable Production Alarms option if you want to trigger Production alarms. If this option is selected, an alarm will be triggered whenever the production rate exceeds the specification limit defined by the Specification Variable you selected in step 5. To view these alarms on the Alarm display, you must select this unit on the Unit tab when configuring the Alarm display. For more information, see the topic, Configuring an Alarm View Display.
Alarms are not tied to the OEE calculation.
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In the Calculation Interval box, type the number of minutes that will determine how often the calculation is triggered.
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In the Calculation Window box, type the number of minutes that defines the time period over which values will be averaged.
Enable Production Rate Alarms turns on the calculation of Percentage Production Rate compared to the Production Rate Percent Specification. If the Calculation Interval is 5 minutes and the Calculation Window is 1440, then the Total Percentage Production Rate calculation will be calculated every 5 minutes over the 1440 minute interval. These values will get compared to the Production Rate Percent Specification to determine if the rate is to low for each interval.
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Click Save when finished.
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Click the Close
button close the Unit Properties Configuration dialog box when completed.
To Set the Waste Metrics for a Production Unit
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On the Production Metrics tab, click the Waste tab.
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Select the Waste Percent Specification. Click the Browse button
to select the Central Specification Variable that contains the specifications. The Waste Percent Specification is used to set a specification limit to alarm against when a certain percentage of waste is exceeded for the interval.
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Select the Enable Waste Alarms option if you want to trigger Waste alarms. If this option is selected, an alarm will be triggered whenever the Waste rate exceeds the specification limit defined by the Specification Variable you selected in step 2. To view these alarms on the Alarm display, you must select this unit on the Unit tab when configuring the Alarm display. For more information, see the topic, Configuring an Alarm View Display.
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In the Calculation Interval box, type the number of minutes that will determine how often the calculation is triggered.
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In the Calculation Window box, type the number of minutes that defines the time period over which values will be averaged.
If the Calculation Interval is 5 minutes and the Calculation Window is 1440 then the Total Percentage Waste calculation will be calculated every 5 minutes over the 1440 minute interval. These values will get compared to the Waste Percent Specification to determine if the acceptable amount of downtime for each interval has been exceeded.
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Click Save when finished.
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Click the Close
button close the Unit Properties Configuration dialog box when completed.
To configure for non-productive time
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On the Production Metrics tab, click the Non-Productive tab.
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Under Category, select Non-Productive Time.
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optional: Under Reason Tree, select the reason tree for the non-productive time. If you do not assign a reason tree, the Reason list in the New Non-Productive Time dialog box will be empty.