ShopFloorManager Technotes
OEE Discrete Includes ShopCharts & ShopReports PDF-Version
Use ShopReports for Detailed Historical Reporting of OEE Discrete Effectiveness
Use ShopCharts for Real-Time Collecting, Displaying & Reporting of OEE Discrete Effectiveness
Supports Windows 8TM, Windows 7TM & WindowsTM XP including Support for Terminal Server 2003/2005/2008

OEE (Overall Equipment Effectiveness-Utilization)

OEE is a measurement of how effective(Actual Usage vs Maximum Possible Usage) you are using your equipment. By partitioning the collected equipment metrics into several different categories ( Availability; Performance & Quality) you can more easily evaluate where improvements in "Effectiveness" can be achieved.(i.e. machines, cells, assembly lines, etc.).

OEE as a Concept is simple But!

All though the OEE concept is simple Applying it to Continuous & Discrete Processes is usually quite Different!

OEE for Continuous Processes

• Real-Time Gauging/Inspection: (Quality: Good-Bad Part Determination)
• Real-Time Process stoppage sensing(Availability: Running-Idle Time Determination)
• Real-Time Process Cycle time collections(Performance: Cycle Time Under-Over Standard Time Determination).

OEE for Discrete Processes

• Non Real-Time Gauging/Inspection: (Quality: Good-Bad Part Determination)
• Non Real-Time Process stoppage sensing(Availability: Running-Idle Time Determination)
• Real-Time(Sometimes) Process Cycle time collections(Performance: Cycle Time Under-Over Standard Time Determination).

Note: Capturing OEE "Events-Times" & displaying all OEE Categories in Real-Time is not always possible or practical in discrete manufacturing. Typically in Discrete Manufacturing Inspections are usually performed after the fact(use of Probes can rectify this), process stoppages reasons/times are usually input manually after the fact and collecting/calculating standard vs actual process times can be more problematic. So, displaying REAL-TIME OEE results in Discrete Manufacturing can be a Challenge!

ShopCharts' OEE Discrete

Using ShopCharts' OEE Discrete you can immediately Capture & Display OEE for each piece of Equipment giving you a Real-Time View of your Shop's Machine by Machine Processes! Using ShopCharts OEE you will know if each piece of Equipment is meeting it's Real-Time OEE Goals. Thus, if it's Broke Real-Time, you can Fix It Real-Time! Best way to improve your Company's OEE!

In Discrete Manufacturing which is better, ShopCharts' OEE Discrete or Typical OEE?

Is it better having a single OEE Chart Representing OEE Averages for all the pieces of Equipment or knowing the Real-Time OEE for each piece of Equipment? A typical OEE averages all of the OEE Metrics so what you are viewing is an average efficiency of your overall Shop which clouds how each piece of Equipment is Running Real-Time! Is it better to know that a specific Equipment's Active Process is meeting its OEE "Goals" Real-Time or to analyze it after the Fact? Hindsight is great for fixing the blame but not alway great for fixing an inefficient Process! If it's Broke Real-Time, Fix it Real-Time!

OEE Discrete Real-Time Charts: A Real-Time OEE Window into Manufacturing!

How ShopFloorManager Implements Practical OEE

ShopFloorManager Runtime [Machine Status]

Note: The First thing you need to do to improve OEE is increase your equipments usage. In other words make sure it's Operating Now! ShopFloorManager Runtime provides a Machine Status Display showing all of the selected Machines' Current State, Running, Stopped including specific Cycle Event Details!

ShopCharts - "OEE Discrete"

Note: ShopCharts' OEE Discrete Chart provides all the details you need to determine if your Specific Piece of Equipment is meeting the Real-Time OEE "Goals" as set by your Company. You can run as many Individual Charts for each Machine Tool Simultaneously. They are automatically updated every 60 seconds or you can refresh them immediately! For Details see the various Chart Categories below!

Pie Chart Layout

Machine Name

The Name of the Machine that this OEE Chart is associated with is located in the Upper Left Hand Corner and in the above Chart is called: OKK HZM #1

Chart Name(Filter)

The Chart Name is really the Monitoring Program Name and the one you chose to Run. It is located in the "Middle" of the Chart. For this Chart it's named "OEE Cycle"!

OEE Metrics

This is located in the upper Right Hand Corner of the Chart. See the various Labels for the OEE Factors below this Label.

OEE Events(Data Point Details)

This Window contains all of the Events that were issued against this instance of the OEE Chart. All of data collected within the selected Time Frame is used in the Calculations but only the Events that were generated during this instance are displayed. Cycle Events that take longer than the Standard Time are recorded in "Red"!

The Pie Chart

The Pie Chart itself is divided into two areas
The Blue designates the percentage of total time of the selected Time Frame that the Machine tool was meeting the Standard Cycle Times.
The Red designates all Idle Time such as downtime, setup, Maintenance, etc. including any time of a cycle that exceeds the Standard Time!

ShopReports Machine Event Sessions Reports - "OEE Cycle"

Note: ShopReports Machine Event Sessions Report provides the complete summary of all of the cycles that are used to calculate the OEE Report for the selected Machine Tool over your selected Time Frames! At the bottom of the Report you can view the OEE Summary & and OEE Pie Chart!

OEE Cycle Report

Machine Name

The Name of the Machine that is associated with this OEE Chart. The Name of the Machine For this Report is OKK HZM #1!

Data Item

The Event Program you created for collecting OEE data for this Chart. In the above Chart it is called OEE Cycle!

Selected Records-Headings

• DNC File Name:
• Version: Indicates the version of this DNC File
• Id: Unique key for database management
• Status: Indicates if there was a Start & End Cycle for this Record
• Idle Start: Immediately after Cycle End. May be same as Cycle Start if Cycle starts immediately after Cycle End!
• Idle End: Not displayed but is the same at Cycle Start
• Cycle Start: Start of the Cycle
• Cycle End: End of the Cycle
• Cycle Time: Difference between Start & End
• Idle Time: Total Idle time between active Cycles

OEE Summary

This Window contains all of the Events that were issued with this instance of the Chart. All of data collected within the selected Time Frame is used in the Calculations but only the Events that were generated during this instance are displayed. Cycle Events that take longer than the Standard Time are recorded in "Red"!

The Pie Chart

The Pie Chart itself has two areas that are displayed/colored.
The Blue designates the percentage of total time within the selected Time Frame time that the Machine tool was meeting the Standard Time.
The Red designates all Idle Time such as downtime, setup, Maintenance, etc. including any time of a cycle that exceeds the Standard Time!

ShopReports Machine Events (Serial Numbers) Report - "OEE Cycle"

Note:

1. The ShopReports' Machine Events (Serial Numbers) Reports provide complete details for each of the Events that are used to generate any Report within ShopReports. These Detailed Events include as a minimum all the Start & End Event Sets as shown above. The number of Sets depends on your selected Time Frame!
2. If you have created other Events, "Marks", within the Monitoring Program you will find these Events are also detailed and included. These Other Events(Marks) could be Probe information, Tool Changes, Entering/Leaving Sub-Routines, Down Time Reasons, etc. If you need "Details" for any specific Cycle you will find it here!

OEE Calculations & ShopReports' OEE Details

ShopReports' OEE

Real-Time OEE Use

The most effective use of OEE is to display Real-Time OEE Factors as they occur on specific pieces of Equipment. In General the two OEE Factors that can be collected & display in Real-Time in a typical Discrete Manufacturing Environment are Cycle Times & Idle Times. ShopFloorManager's ShopMonitor can capture these Events in two basic ways:

Capturing Real-Time OEE Events

1. ShopFloorManager can Capture, Display & Store Production Cycles Generated by CNC Macros-DPRNTs(In N/C Files)!
2. Using ShopFloorManager's ShopMDI Enter Production Information(Events) Directly so ShopFloorManager Captures, Displays & Stores these Events!

Relevant OEE

For displaying relevant OEE (The here and now) in ShopFloorManger use ShopReports' Filter to select the various Settings such as the CNCs, Immediate Time Frames: Today; Shifts; Custom Hours, N/C Files, Events, etc. so when you select an OEE Chart to display you will be displaying OEE that is based on those immediate OEE Factors and not on averages over a large time frame which obfuscate what is happening NOW! You will see problems "Right Now" so you can address them "Right NOW"!

Historical OEE Use

If you want to display OEE Factors over a longer time frame use the same procedure as above but set the Time Frames for a Historical View! Start with a Time Frame before the Present and select any ending date of your choice. If you don't select an ending date or select an end date later then today, OEE will displayed a Historical average of all the Factors over the selected Time Frame up to NOW!. If there is no end date or the end date is in the future OEE will continue to collect and average OEE Time Factors.

Availability

Using ShopFloorManager's Monitoring Module you can create a Event Program which can be named "Availability". You can add Categories within this Monitoring Program to reflect the various downtime reasons you would like to collect such as Setup, Maintenance, Waiting for Material, etc. This program would be activated by ShopMDI and allow a ShopFloorManager User to enter all of the downtime reasons for use to generate Historical Reports & for Real-Time Charting while the Machine Tool is not being Operated. If you don't use this Program, ShopFloorManager's implementation of OEE will still collect the downtime data but places in under one category, "Idle".