Main Fields/Controls

The Factory Monitoring routine provides the following options of fields and controls:

If a Capacity Unit is specified for the work center of the machine, the capacity indicated in the Machine is considered.

Examples:

Work Center - Oven – Capacity Unit - KG

Machine – Oven1 – Work Center Cap = 5,000

Time Available (Calendar x Cycle) = 5 hours

5 hours x 5,000 kg = Capacity 25,000 kg

Work Center - Oven – Capacity Unit not defined (blank)

Machine – Oven1 – Work Center Cap = 5,000

Time Available (Calendar x Cycle) = 5 hours

5 hours x 1 = Capacity 5 hours

When the Capacity Unit is not defined, all calculations are performed in hours.

Sum of all the daily capacities shown in the detail.

Project Capacity - (Scheduled Stops x Machine Capacity)

Where:

Scheduled Stops = Time of Scheduled Stops, for example: Preventive Maintenance. (Expected Stop Time)

Difference between Effective Capacity and Unscheduled Stops. In this case, we will have the actual capacity volume to be used for manufacturing.

Actual Volume = Project Capacity – (Total Stop Time x Capacity Factor)

It represents the ratio between Actual Production and Project Capacity.

Actual Availability = Actual Production / Project Capacity * 100

It may be calculated either when the capacity unit is not informed:

Use = (Actual Production - Hours without Report) / Actual Production

Or when the capacity unit is informed:

Use = Sum (Amount Processed) / Actual Production

Where:

Amount Processed = Capac. Used in Operation / Operation Units * Split Expected Amount / Split Reported Amount

Represents the ratio between amounts scrapped and amounts reported.

Quality = ((Sum of Amounts Reported - Amounts Scrapped) / (Sum of Amounts Reported)) * 100

In other words: Quality = Amount Approved / Amount Produced

Actual quality rate. This is not about the quality rate when the product leaves the factory, but the quality of processes, not considering the rework from defective products.

It represents the ratio between the standard operating time and the sum of actual operating time. You can even consider the scrap factor to determine the effectiveness.

Effectiveness = Sum of Standard Operating Time / Sum of Operating Time * 100

If the parameter Setup Changes Effectiveness is selected, the setup time must be considered:

Effectiveness = (Sum of Standard Operating Time + Standard Setup Time) / (Sum of Operating Time + Setup Time) * 100

Considering the Scrap factor - Quality:

Effectiveness = Sum of Standard Operating Time / Sum of Operating Time * 100 * Quality

The net effectiveness measures the performance at uptime, not considering the actual availability factor as the Overall Equipment Effectiveness does.

Effectiveness * Actual Quality / 100

The overall effectiveness measures the global performance of a process or system. It is one more contribution from the Japanese management. Initially developed to support the Total Productive Maintenance (TPM) philosophy, OEE has been gradually applied to overall situations, not limited to industrial processes. OEE is measured this way:

OEE = % Effectiveness * % Availability * % Actual Quality

TEEP stands for Total Effective Equipment Performance. This indicator is recommended exclusively to measure critical resources. All the possible production time is considered as resource available time (including scheduled stops); thus, this indicator provides the performance percentage in relation to the resource total time.

Effectiveness * Actual Quality * Use * Actual Availability / 1,000,000

Production pace, which is the capacity, in amount of parts to be produced per minute. Actual Capacity * 60 / Amount Reported

See more details in the BTS concept.