the pi system in the manufacturing line calculating oee ......what is overall equipment efficiency...
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#PIWorld ©2019 OSIsoft, LLC
The PI System in the Manufacturing Line –Calculating OEE Across Your Factory
Paula Baquer
Customer Success ManagerGothenburg, 17th September 2019
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#PIWorld ©2019 OSIsoft, LLC
Manufacturing
Challenges
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Manufacturing Challenges
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Run Time
Uptime
Planned Downtime
UnplannedDowntime
Visibility
Reason Code
• Downtime
• Losses
Line/PlantComparison
ROI Measurements
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Scheduling
Product Changeover
Demand vs. Capacity
Slow Start-up
Throughput
Yield
Units produced
Speed
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Downtime time-frames
Low product quality
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How OEE can help you?
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What is Overall Equipment Efficiency (OEE)?
“Standard to measure manufacturing productivity that identifies the percentage of manufacturing
time that is truly productive”
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OEE Availability QualityPerformance= x x
100% OEE
No Stop Time
As fast as possible
Good Parts Only
Running time Running speed Good Parts
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Typical Losses
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Net Run Time
Fully productive Time
Run Time
Planned Production Time
Time prospective
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All Time
Scheduled
Loss
Availability
Loss
Performance
Loss
Quality Loss
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•Visual del mon amb les plantes i els seus OEE
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•Visual de la planta
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Recipe to implement OEE
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Recipe to implement OEE
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PI Analytics
1. Connect, Collect&Store 2. Contextualize 3. Execute condition logic
4. Track Alerts, Downtime & Notify
PI Event Frames
PI Vision
PI Datalink
BI Tools
5. Visualize
Take Action, Implement Changes,
Continuous improvement
PI AF
Connect, Collect &
Store
Assign Context
Execute Condition
Logics
Track Alerts, Downtime &
NotifyVisualize
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Shop Floor Structure
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1. Connect your sources
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Production Equipment
PLC 1
SCADA / PLCs / DCS / OPCPLC 2 PLC 3
WIN CC 1 WIN CC 2
Turning Chamfering Grinding Heating Polishing Honing
PI Interfaces & Connectors
PI System
Real-Time
InformationRunning
Time
Machine
StateBad Part
Counts
Good Part
CountRejects
Solutions OEEAvailability
Performance
Quality
Equipment
Line
Plant
KPIsDowntime
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2. Build your context
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All Equipment View
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Area View
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3. Execute Condition Logic @ Template level
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Availability Operating Time / Planned Production Time
Performance Part Count / (3600/Cycle Time)
Quality Good Part Count / Part Count
OEE Availability*Performance*Quality
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Roll up calculations to station, lines, groups
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Availability
Performance
Quality
OEE
Station
Availability
Performance
Quality
OEE
Line
Equipment
Availability
Performance
Quality
OEE
Equipment
Availability
Performance
Quality
OEE
Equipment
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Backfill the results to get data from the past!
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4. Track, Alert & Notify
•Use Event Frames to track downtime and establish reason codes.
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Event
Start Time
End Time
ContextmyEvent
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Product XYZ (1)
Events will help you to…
1) Perform Asset Comparisons
2) Compare similar behaviours
3) Track downtimes
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Use Enumeration Sets as reason codes
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5. Visualise
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Multi-state symbols
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View and respond to events
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Excel Reporting using PI DataLink
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Build dashboards with drill-down capabilities
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#PIWorld ©2019 OSIsoft, LLC
PI Integrators enable Advanced Analytics
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Apply Algorithms
Predict with known
levels of accuracy
Correlate
Identify patterns
visually
Why it matters?
Data has connection to the physical world
Required for feature selection
Same type of equipment will have
different measurements
Time-series data is not naturally aligned
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A success in just 3 months!
•Pilot site Performance improvement of 40%
•Pilot site Availability improvement of 21%
•Pilot site OEE improvement of 30%
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CHALLENGES SOLUTION BENEFITS
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▪ Downtime
▪ Start-up Time
▪ Product Rejects
▪ Maintenance Costs
Summary
▪ Capacity
▪ Production
▪ Equipment efficiency
▪ Quality
▪ Unable to reach the production target.
▪ Unable to explain reasons on bad pieces produced.
▪ Unable identify downtime reasons
▪ Lack of reporting and analytics capabilities
▪ 5 step Recipe to success
▪ capture information across the whole site.
▪ Standards to compare effectively equipment across sites.
▪ Track downtime events and associate reason codes.
▪ Visibility across production line in real-time.
▪ Platform for global data management, reporting and fast access for continuous process improvement.
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And you? Are you ready to transform your world?
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Resources to Help you Succeed
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Where to start?
https://pisquare.osisoft.com/community/all-things-pi/af-library/asset-based-pi-example-kits
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Don’t forget that partners are also here to help!
Condition data
Context
KPIs
Alerts
Displays
Partner
Integration
with other
modules
Custom
solutions
Turn-key solutions and predictive
models
Start OEE with
out-of-the-box capabilities
PI System foundation
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… and during PIWorld? Tech-Lab!
Using AF to Analyse
Asset Performance
• When: Thursday 19th September 9AM-12.15 PM
• Where: Lab 3, GT: J2, 2nd floor
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#PIWorld ©2019 OSIsoft, LLC
Let’s stay connected!
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Paula Baquer
pbaquer@osisoft.com
Customer Success Manager
OSIsoft
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#PIWorld ©2019 OSIsoft, LLC
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name & company
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