Improving Overall Equipment Effectiveness (OEE) Unrestricted © …€¦ · Improving Overall...

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Improving Overall Equipment Effectiveness (OEE) usa.siemens.com/digital-factory Unrestricted © Siemens Industry, Inc. 2018

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Improving OverallEquipment Effectiveness(OEE)

usa.siemens.com/digital-factoryUnrestricted © Siemens Industry, Inc. 2018

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Improving Overall Equipment Effectiveness (OEE)

Evaluating equipment’s ability to perform well at the lowestoverall cost is a real challenge in manufacturing plants. Moredata than ever before is available; capturing and analyzing theright data can be more difficult.

Today’s Agenda1) Introduction to OEE2) Review Ways of Improving OEE3) Customer Benefits

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⋅ Application and solutionapproach to customerneeds

Develops repeatablesolution based uponapplications and value fit.Develops configurators, how-to tools

⋅ Provides field applicationsupport for technologyproducts

Focus on Simocode, safety,Sirius networks, Softstartersstandards (Synergy / ICP),and FastBus

⋅ Leads CP social mediaAmbassador Program

Online awareness and promotionof CP through SN, in collaborationwith other DF businesses

⋅ Drives ControlsTechnical communityknowledge swaps

Manages team of 25channel, and xBU technicalcommunity which supportCP in the market

⋅ Territory aligned to pursuehigh value conversions

Regionally aligned to support fieldand pursue high value conversionaccounts

⋅ Increase revenue andcommunity within Synergyprogram

Own the control panel Shiftfrom Synergy signage torevenue growth

Applications, Digitalization, and Design

Application Resource Center

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Introduction to OEE

Overall Equipment Effectiveness (OEE) is ameasurement of performance for industrialequipment.

It is based on 3 major components:Availability, Performance and Quality

A P Q OEEX X =

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Availability – A percentagemeasurement based on how muchtime a machine is “available” to runproduction versus a fixed period oftime

Availability =Available timeFixed Period

6 hours8 hour shift

= = 75%

Introduction to OEE

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Performance – A percentagemeasurement based on the actualproduction rate versus a fixedmaximum production rate.

Productivity =Product produced

Max. Product80 units/ hr.

100 units/ hr.= = 80%

Introduction to OEE

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Quality – A percentage measurementbased on good parts versus total partsproduced

Quality = Good producedTotal produced

90 units100 units

= = 90%

Introduction to OEE

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Introduction to OEE

IDA – A simple methodology for drivingimprovement of OEE.It stands for:Information, Decision and Action…drive Results

I D A RX X =

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Plant Floor

Corp HQ

OE

ED

ata

Improved trigger mechanism to record data

Raw Data vs. Knowledge

Barriers

Barriers to Improving OEE

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0 6 8Time (hr.)

Availability

Availability =Available timeFixed Period

6 hours8 hour shift

= = 75%

(How do you improve this)2 Hours of Downtime

Introduction to OEE

Let’s Focus on the Data Trigger

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0 6 8Time (hr.)

AvailabilityWaiting for Maintenance

Repair Time

Operator Idle Time

Does this “Availability” measurement tell the whole story?

Introduction to OEE

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Improving OEE

The First Step in improving “Availability” is by improving“Accountability”.(Identifying Who does What and When)

How Do We Currently Do This?

1) Key Switch 2) Password 3) Paper Log

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The First Step in Improving Availability is by ImprovingAccountability.(Identifying Who does What and When)

How Can We Do This Better?

RFID Key Switch

Improving OEE

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1) Common 22mm pilot device size

2) Communicates to any PLC/DCS via IO-Link

3) Keys are read only

4) Unique shape provides protection against

tampering or duplication

5) Easily attaches to a key ring

6) Unique Hex code ID is assigned at the factory

Improving OEE

RFID Key Switch

RFID Key

04 D7 C8 18 04

Basic Characteristics

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Improving OEE

Key #

04 D7 C8 18 04

04 9A 45 1A 04

C1 F5 C8 18 04

40 D9 C8 18 04

Unique ID

1

2

3

4

• Every key has a uniquehex code ID assignedat the factory

• Similar to a MAC ID toEthernet products

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Improving OEE

• PLC matches ID codefrom the RFID key topreviously storedvalues to identify owner

42 FB 01 1A 04

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Improving OEE

• PLC records date, timeand action every time akey is inserted orremoved

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Improving OEE

ActionWho

04 D7 C8 18 04

C1 F5 C8 18 04

Operator inserts key atstart of shift

Operator removes key andrequests maintenance

Maintenance inserts key andbegins maintenance

Maintenance removes key andcompletes maintenance

What is Recorded in the SystemWhat

Start of Shift

Maint. Req.

Maint. Started

Maint. Completed

When

8:00 am

9:00 am

10:45 am

11:00 am

04 D7 C8 18 04

C1 F5 C8 18 04

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Improving Availability

0 6 8Time (hr.)

AvailabilityWaiting for Maintenance (Sneezy)

Repair Time

Operator (Doc) Idle Time

Now “Availability” measurement tells a more accurate story?

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Improving OEE

• WinCC HMI softwaredisplays recordedevents

WinCC

Solution – Raw Data vs. Knowledge

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Improving OEE

WinCC Performance Monitor Analyzes the Data

Solution – Raw Data vs. Knowledge

• The WinCC Performance Monitor offers reliable analyses on:

• OEE - Overall Equipment Effectiveness

• MTBF - Mean Time Between Failures

• MRT - Mean Repair Time

• and further Key Performance Indicators (KPI).

• The production equipment can be defined individually depending on thespecific plant.

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MindSphere

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MindApps‒Use apps from Siemens, partners or develop own apps‒Gain asset transparency and analytical insights‒Subscription based pricing model

MindSphere‒Open interface for development of customer specific apps‒Various cloud infrastructures: SAP, AtoS, Microsoft

Azure offered as public, private or on-premise (planned)

MindConnect‒Open standards for connectivity, e.g., OPC UA‒Plug & play connection of Siemens and 3rd party products‒Secure and encrypted data communication

Improving OEE

Solution – Raw Data vs. Knowledge

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Field Asset –SIMOCODE

MindConnect Nano

Internet RouterOptional: Proxy

Internet

MindSphere - Siemens Cloudfor Industry

Production / Machine Network

Corporate / Office Network with route to the internet… or direct internet access, e.g. via a DSL modem

PROFINET OPC

PLC/DCS

Improving OEE

Solution – Raw Data vs. Knowledge

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MindSphere

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MindAppsData analytics applications to increase uptime,optimize energy efficiency and enhance cybersecurity.

MindSphere – the cloud-based, open IoT operating system

Siemens OEM Apps App developers End-customers

Siemens products and systems or 3rd party products and systems3rd Party AppsAtos AppsSiemens

MindAppFleet-

manager

Build yourown

Dashboard

OEM App

Analytics

App

Mobile PlantDashboard

ProductionConfirmation

Manufact-uring

Sustainability

AugmentedQuality Mgmt.

Worker

Defect Reporting

Solution – Raw Data vs. Knowledge

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Solution – Raw Data vs. Knowledge

Improving OEE

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1) New keys can easily be assigned by a

supervisor

2) Lost keys can be identified if ever used

again

3) Multiple Keys can be assigned to a single

owner

4) Unique shape provides protection against

tampering or duplication

RFID Key Switch

RFID Key

04 D7 C8 18 04

RFID Keys

Benefits

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• Makes it possible to show the weak points of the production and to derivesuitable optimization potential.

• Flexible – Individual calculation of plant specific performance indicators withinSIMATIC WinCC

• Recognizing performance indicators within the content e.g. quality per vendor

• Analyzing of the performance indicators and displaying them as bar- or Gantt –diagram or as a table also using the Web

• Viewing everything at any time – Target–group oriented analysis reports

• Expandable– Adding of performance indicators within existing plants without anyloss of production

Benefits

WinCC & Performance Monitor

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PerformanceManagement APP

Alarm and EventManagement APP

Shift Calendar APP

Energy ManagementPRO APP

SIMATIC SystemDiagnostic APP

MindSphere

Customer focus: System integrators, machine manufacturersFirst industry-specific applications: automotive, F&B, aerospace

Connectivity • Optimized engineering packagesfor integrated configuration

Planned for TIA Portal V15 and following TIA Portal versions

Firs

tDF

FAap

ps

Part

ner

apps

Min

dApp

Benefits

MindSphere – Cloud Based Solution

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Benefits

Siemens Solution is Scalable:

Production Line

Machine

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Benefits

Siemens Solution is Scalable:

Entire Plant

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Benefits

Controls Automation

+

HMI/SCADA

+

Siemens Can Provide a Complete Solution:

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Thank You

John BurnsDF CP

5300 Triangle ParkwayNorcross, GA 30092

Phone: +1 (678) 575-3086

E-mail:[email protected]

www.usa.siemens.com

www.usa.siemens.com/sirius-act

www.usa.siemens.com/wincc

www.usa.siemens.com/mindsphere