Solution Overview
The production companies regardless of the sector faces the same sort of challenges: (i) Improvement efficiency (OEE) and better waste downtime management, (ii) Optimizing production in time and flexible machines management, (iii) SCADA and business systems integration into one aggregated real-time monitoring solution. OEE & Downtime Tracking Starter Pack helps batch production companies to solve these issues by focusing on operational effectiveness and achievements thanks to: (i) Integration of various IT and OT systems into one central monitoring platform providing insight for both plant personnel and managers – optimized working conditions of whole production (machines), (ii) Integration of production process with business systems – improved correlation between orders and data from production (machines).
The goal of starting pack of OEE & Downtime Tracking is to deliver in very short Time-To-Market, the batch production company operational and business value through: (i) Online KPIs monitoring of whole batch production in one consistent tool, resulting in better decision making in terms of improving production effectiveness, (ii) Access to aggregated data (per product, machine, line, shift, etc.) allowing localizing, tracking and preventing from downtimes, resulting in reducing of products rejections, (iii) Automated reporting of production and quality KPIs and downtimes (e.g. every shift), resulting in avoidance of manual reporting of the production by operators.
Solution Approach
The aim of the system is to collect real-time data from machines, devices and production management systems as well as online monitoring of KPIs: (i) OEE and its trend (increasing / decreasing), (ii) Total production, (iii) Rejected production, (iv) Good production, (v) Progress of order fulfilment, (vi) Recent and most frequent downtimes. KPIs are calculated and visualized in terms of current batch / order, however, due to the fact that the full data history is stored, it is also possible to calculate and visualize these parameters in terms of specified period of time, e.g., hour, shift, day, etc. Additionally time-dependent parameters are calculated in terms of particular items like machines, lines, technology or whole company and it is possible to correlate them with orders / product types and downtimes. Production reports are distributed periodically to selected users via email. The basis of the application is the OSIsoft PI System. It implements a central data repository, the main analysis engine and the visualization platform powered by PI Vision. For reporting purposes, tools such as Power BI, Power Pivot or others may be used depending on the client's needs and preferences. Implementation of OEE & Downtime Starter Pack in short Time-To-Market – in average 2 months, assumes the delivery of ready-to-use system with all necessary OSIsoft PI System components and professional services of configuration of the data model reflecting the client's environment.