Oee on hana overall equipment effectiveness overview aug 2012 (2)

OEE on HANAOverview of the Solution Capability and ArchitectureSAP Manufacturing Performance ManagementAugust 2012

© 2011 SAP AG. All rights reserved. 2

What is OEE?

� OEE (Overall Equipment Effectiveness) can be described as a universally

accepted set of metrics that bring clear focus to the key success drivers for

manufacturing enterprises.

� OEE is the measurement technique that has been in practiced for many years,

albeit with a narrower purpose. Historically, OEE was used as a top level summary

view of capacity and its utilization. In recent years it has reappeared but with a more

valuable multi-level view of the business, placing emphasis on the underlying issues

that limit performance. The resurgence of OEE is doubtless related to its ability to

plainly portray the opportunities for improvement that exist for all manufacturers.

� Functionally, these metrics provide the basis by which excellent manufacturers

can systematically direct their business towards attainment of critical objectives like:� Improving Operating Margins

� Optimized Competitive Position

� Maximized Utilization of Capital

Internal and Confidential


OEE on HANAOverview

Value Added for Customer

� Global planning with real time visibility to distributed plant level execution

� Reduced manufacturing cost through waste reduction

� Maximize return on capital investment by improving utilization

� Increased customer satisfaction by constant monitoring on Speed of production and Quality

� A tool which drives continuous improvement of manufacturing performance

CUSTOMER VALUE

SHORT DESCRIPTIO

N Context/Use Case

� OEE is a Plant Performance Management Solution with:

� Universally accepted set of metrics

� Clear focus to the key success drivers for manufacturing enterprises

� Emphasis on the underlying issues that limit performance

� A “Comprehensive Loss Analysis” tool for the manufacturing shop floor

� Real time, scalable and extensible solution

� Operator grade User interface for shop floor execution


Overall Equipment Efficiency (OEE) on HANA

Leverage immediately the power of In-Memory for analytics for OEE

� HANA provides the best environment for OEE from a technical perspective:

A combination of data aggregation mechanisms with business logic & algorithms. It allows flexible drill

down capabilities from the top aggregated level down to the individual record.

� No intermediate step on classical DB, no future migration for customers

� With HANA customers can easily build additional manufacturing analytics on top of OEE

� Provide one tool & user experience for both enterprise and plant reporting based on up-to-date

technologies

HANA will be the basis for future real time and predictive operational intelligence

� OEE is the first step towards an In-Memory Manufacturing Performance Management solution

� Real time and predictive Analytics will be further steps leveraging the power of HANA to allow improved

process yield, resource consumption, product and process quality through real-time monitoring of

production performance

Build OEE directly on In-Memory is the first step towards a new era of Manufacturing Analytics and Operational Intelligence

KEY MESSAGE


OEE Key Stakeholders & Objectives

Ensure effective manufacturing execution

Ensure smooth production run

Define/Implement successful Operation Strategy

How do I meet all requirements and maximize productivity ?

How do I gain visibility to the status of manufacturing performance across plants ?

How do I manage manufacturing operations efficiently and avoid negative impact to the plant image?

How do I execute my daily tasks efficiently ?

�Reduce operating costs

�Increase true capacity/decrease time to produce

�Increase return on assets

�Better manage and allocate capital

How do I ensure safe operations through cost effective maintenance and reliability programs?

Ensure daily targets are maintained

�OEE Metrics

�Production performance

�Maintenance performance

�Capacity Utilization

�Asset Utilization

�Mfg Costs

�Production and Shift performance

�Output against Targets

�Shop floor losses

�Throughput, Utilization

�Maintenance Performance

�Downtime Analysis

�Machine Breakdowns

�Ratio Planned / Unplanned Maintenance

�Meantime between failures

�Work Performance

�Setup times

�Throughput

�Shop floor losses

COO

Maintenance /

Engineering Manager

KPI´s:

Business Needs:

VP Operations Plant Manager / Plant Supervisor Operator


Customer Challenges

� Absence of a standardized scalable tool across manufacturing

facilities to measure and compare performance

� Challenges in finding hidden areas for possible improvements on a

continuous basis which limits performance

� A near-real time analytics to analyze shop floor data

� Driving Business Transformation on the shop floor

Key Product Features

� Deliver analytical capabilities against plant and other business data

� Leverage existing ERP master data already available with almost

no duplicate configuration

� Close the loop via monitoring and alerts

� Global plan to get executed in large distributed factories

� Enables measurement of plant performance resembling the plant

actual hierarchy

� Enables collection of plant data analyzed across customer defined

multi-level loss trees in real time – Manual and automatic data

collection

� State-of-the-art operator grade User Interfaces for real time data

collection

Role:Plant Manager, Operator, LineSupervisor, VP Operations, Manufacturing Heads

Target Segment

Installed base and net new customers in the Manufacturing Industries

Scrum team

1 Scrum team7 developers, 1 PO, 1 Architect

Planned RTC

27 May 2013

UI Type HTML5

Integration SAP MII

Analytics SAP HANA

OEE on HANA Customer Challenges and Product Features


Overall Equipment EffectivenessTime Elements of OEE

Efficiency Loss

(ELrep)

Speed Loss(SL)

Quality Loss (QL)

In-line

Rejections

Off-line

Rejections

NET OPERATING TIME / TARGET HOURS

(NT) or (TH)

Fully Productive Time /

VALUE OPERATING TIME

(VT)

Performance

Loss

(PL)

PLANT OPERATING TIME / TOTAL TIME

(TT )

PLANNED PRODUCTIVE TIME / LOADING TIME /GROSS PRODUCTION HOURS

(LT) or (GPH)

Shutdown Losses /

Planned Downtime (SD)

Idle Time (IT)

EQUIPMENT PRODUCTIVE TIME /

OPERATING TIME / NET PRODUCING HOURS

(PT) or (NPH)

Downtime losses /

Unplanned Downtime

(UD) or (DH)

* Definition of the time elements are flexible

* Reason code definitions are multilevel


Overall Equipment EffectivenessAddressing the “Major Losses” of Production

� Reducing planned downtime due to meetings, breaks, material shortages, maintenance (Utilization)

� Eliminating breakdowns and unplanned downtime through root cause analysis (Availability)

� Tracking and reducing changeover, set up time and adjustments (Availability)

� Reducing minor stops for misfeeds, blocks, jams that do not require maintenance (Performance)

� Reducing speed loss and anything that prevents running at maximum speed (Performance)

� Reducing scrap and rework due to start up (Quality)

� Reducing scrap and rework during steady state production (Quality)

Efficiency Loss

(ELrep)

Speed Loss(SL)

Quality Loss (QL)

In-line

Rejections

Off-line

Rejections

NET OPERATING TIME / TARGET HOURS

(NT) or (TH)

Fully Productive Time /

VALUE OPERATING TIME

(VT)

Performance

Loss

(PL)

PLANT OPERATING TIME / TOTAL TIME

(TT )

PLANNED PRODUCTIVE TIME / LOADING TIME /GROSS PRODUCTION HOURS

(LT) or (GPH)

Shutdown Losses /

Planned Downtime (SD)

Idle Time (IT)

EQUIPMENT PRODUCTIVE TIME /

OPERATING TIME / NET PRODUCING HOURS

(PT) or (NPH)

Downtime losses /

Unplanned Downtime

(UD) or (DH)


Overall Equipment EffectivenessStandard OEE Calculations

OEE = Availability x Performance x QualityOEE = Availability x Performance x QualityOEE = Availability x Performance x QualityOEE = Availability x Performance x Quality

IT – Idle Time

SD – Scheduled Down

UD – Unscheduled Down

DH – Downtime Hours

SL – Speed Loss

PL – Performance Loss (calculated)

ELrep – Efficiency Loss(reported)

EL = 0

Standard calculations can be configured and extended

OEE Operator UI

Contact information:

F name MI. L nameTitleAddressPhone number


Operator UI for Event Capture

Ability to view real time status and change status of equipment

� Real time red, yellow, green light status of all machines on a line

� Ability to change the current status of any machine (up and down)

� Ability to record speed loss and short stops

� Multi-tiered reason code structure and comments for root cause and corrective action

Ability to indicate start and stop of production

� Record the starting and stopping of production with associated PO number, material, operation, recipe, etc.

� Ability to easily switch between PO’s as production changes

Ability to record production

� Record quantities of good and bad product made and reasons (acceptable vs. avoidable loss)

� Configurable “bad product categories for scrap, rework, waste, rejects, etc.

� Production recorded in both real-time and batch modes


Operator UI for Monitoring Production

Ability to view real time OEE event activity and KPI’s

� Near real time calculations for OEE, Availability, Quality, Performance, up and down time, actual vs. nominal speed, production quantity vs. plan, etc.

� List of all OEE events for all machines the line in chronological order

� Ability to maintain event information (i.e., specify reason codes and comments)

Automated interface to ERP and shop floor systems used to collect shop floor event information used for OEE calculations

� PP and PP/PI interface for production orders

� PM interface for maintenance work orders

� Configurable, standardized interface mechanism for all other plant systems for real-time collection of all OEE event types

Alerting

� Real time alerting for KPI’s out of target with configurable recipients and delivery time frames

� UI pop-up, SMS, email, system generated messages, web services, etc.


Overall Equipment EffectivenessOperator Dashboard

� Real time calculations for the current Order

� Real time OEE calculations happens in HANA

Custom / Extensible Operator Menu

Collapsible SAP provided Operator

Menu

Possible Integration with MII 14.0 Alert

Framework

Line Status

Machine Status


Overall Equipment EffectivenessExtension possibilities of the Operator dashboard

� Right side menu is collapsible and provided by the SAP standard solution, where as the bottom part is for custom extensions

� Custom Extensible Menu for specific activities can be used in different ways, e.g.:

� Manual additional data collection

� Showing additional data from the shop floor, e.g.: Safety Instructions / Control Recipies

� Node specific configuration will give option to define button profiles and follow up link

� On click the pop-up will show up as modal window

� OEE solution will provide templates / interfaces / Queries to facilitate the access of the current order information and posting additional data to the HANA box


Overall Equipment EffectivenessRaising Alert – Possible Integration with MII 14.0 Alert Framework

� Alert can be raised from shop floor by integrating with MII 14.0 Alert Framework feature

� Role specific mail notifications can be configured in the Alert Framework

� Displays of list of Alerts for relevant user roles is also achievable through Alert Framework integration

OEE Dashboards and Analytics




OEE Dashboard and Analysis Examples

Summary Dashboards and Reporting� OEE, Availability, Performance, Quality� Shift Performance

Availability� Actual vs. target overall availability over time� Planned vs. actual productive time (asset utilization) compared to target

� Pareto of downtime loss (time) and frequency (number of occurrences) by reason

� Pareto of Mean Time Between Failure, Mean Time to Repair, Failure Rate, Failure Frequency Rate

Performance� Actual vs. target overall performance over time

� Actual vs. nominal speed and performance compared to plan or target� Speed loss affect on planned production quantity and pareto of reasons. How much

product is being lost as a result?

Quality� Actual vs. target overall quality over time� Good vs. bad product comparison and pareto of reason codes


OEE Analysis Capability

Dashboard views for all OEE KPI’s and associated analysis� Library of pre-defined UI objects for configurable dashboards and reporting by user,

user group, role, etc.� Drill down from one KPI to any related or children KPI’s

Dimensions of OEE analysis� Dill down and across on Hierarchy – business unit, plant, area, line, work center,

equipment� Drill down on time – hourly, shift, day, week, month, quarter, year

� Filter by shift and material

� Comparison views to compare KPI on dimensions of hierarchy, time, material, shift

Alert and Exception Driven� Real time exception driven alerts by user role and delivery mechanism

� Actual vs. target for all KPI’s and highlighted exceptions of missed target, goal, threshold

� Drill down on exception

� Ad-hoc reporting for root cause analysis

Configuration� Pre-defined UI content objects for configuration and extension of customized

dashboards and reports


Loading

time/Gross

Production

Hours

Down

time/Idle

Hours +

Down Hours

Production

time/Net

Production

hours

Net operating

time/ target

hours

Speed loss

+ Efficience

loss

Downtime

losses

Speed

Losses

Quality

Losses

Time dimension

Reporting hierarchy

Materials

Reason codes

Machine Groups

Material Groups?XXX? XX

X X? X X X ?

X X x ?

XXXX

X X X X

X

XX X X X X X X

X XX X X X X X

Time related Financial Loss relatedKPI

Dimension

Overall Equipment EffectivenessAnalytics – KPIs and Dimensions

Sample : Subjected to changes� MTBF ? - Clarifications required

� MTTR ? – Clarifications required

� Perfect Order Deviation - under discussion

� Maintenance Schedule Adherence - under discussion

� Raw material consumption / Utility consumptions - under discussion


Overall Equipment EffectivenessAnalytics – KPIs and Dimensions

Produced

quantities

Rejected

quantities

Accepted

quantities Availability Performance Quality OEE

Time dimension

Reporting hierarchy

Materials

Reason codes

Machine Groups

Material Groups?XXX

X X

XX

X X X ?

? X

X X

X

X X X X X

X X XX X X X

Quantities related OEE relatedKPI

Dimension

Sample : Subjected to changes


HANA Based Report Analysis

HANA Modeling

( Calculation Views )

UI5 Based

Reports

HANA UI Clients

(BOBJ, Analysis

Office etc.)

Other Reporting

Tools (MS Excel

etc.)


HANA Modeling and Analysis

� HANA calculation views would be created for different reports to be consumed from UI clients

� For basic KPIs like Total Production Time, Scheduled Downtime, Availability, Performance, Quality etc. predefined calculation views will be delivered.

� Customers can create any calculation views for any newly defined KPIs and reports.

� UI5 based reports/charts will be provided for basic reports analysis.

� HANA reports can also be consumed by SAP standard UI tools like BOBJ, Analysis Office, visual Intelligence etc. These tools can be easily used by business users without much complexity.

� Its also possible to use third party UI tools like MS excel.


2011-12-

01

2011-12-

02

2011-12-

04

2011-12-

06

2011-12-

07

2011-12-

08

2011-12-

09

2011-12-

10

2011-12-

11

2011-12-

12

1200

004

PACKING_STATION 6 1086 1650 490 10

H_BLENDER 5 8 3 604 895 492 1094 937 70

B_FILLER 4 8 604 297 1278 751 757 131

0

500

1000

1500

2000

2500

3000

3500

4000

Du

rati

on

in

se

con

ds

Reason Code (Blockage) Daily Trend

Duration reported on 3 nodes in hierarchy for Blockage Reason code.

Aggregation is daily from 1 December 2011 to 12 December 2011.

Overall Equipment EffectivenessAnalytics – Sample Charts - Trends


Overall Equipment EffectivenessAnalytics – Sample Charts - Comparisons

Duration reported on all nodes in hierarchy for 2 states: Mechanical and Electrical Breakdown.

Aggregation is monthly for month of December.

OEE Configuration




OEE on HANA Implementation Setup

Internal and Confidential


Overall Equipment EffectivenessConfiguration Items and Activities

� Define Time and Data Collection elements

� Define Machine Groups, Production Modes, KPIs, Reason Codes

� Define the Hierarchy Template

� Define Machines

� Define the Hierarchy – Maintain Bottlenecks, Nominal Rate, KPI Targets

� Publish the Hierarchy

� Excel based data creation utility – Plant hierarchy and Reason code

� Integration module : ERP and MII

� Configure the Operator UI and Activities

Architecture




Overall Equipment Efficiency on HANA Architecture Overview

Central repository

enables global

visibility with full

drill-down

Use of raw data

instead of complex

aggregation and

synch mechanisms

Real-time execution

of complex KPI

calculation

algorithms

Direct machine

connectivity to

collect status

information etc

Data buffering at

plant level through

MII/PCo


Shop Floor

HANA Box

PCo

MII

Notification

Trigger Transaction

Post Event Data to HANA system

� Data collection is possible through manual and automatic interfaces

� Both manual and automatic will have defined set of interfaces provided by the SAP OEE solution

� Example:

� Automatic:

� ReportStatusChane (WorkUnitID, TargetState, OccuranceTime, ReasonCode, ProducitonMode, MarkParentDown )

� Manual:

� ReportStatus ( WorkUnitID, TargetState, StartTime, EndTime, ReasonCode, MarkParentDown )

Overall Equipment EffectivenessData collection Interfaces


HANA Box

Plant - 1

PCo

Overall Equipment EffectivenessData collection Interfaces

Plant - 2

PCo … …

MII

MII MII

… …

ECC

Plant - n

PCo

� MII can post event data to HANA real time and can also buffer when required

� Sample Manual Interfaces

� ReportStatus, GetStatusHistory, MaintainStatusHistory, ReportOperationStart, ReportOperationStop, GetConfirmations, MaintainConfirmations

� Sample Automatic Interfaces

� ReportStatusChange, ReportOperationStart, ReportOperationStop, GetConfirmations

� Maintenance of event data mandatorily required the HANA system to be connected


Overall Equipment EffectivenessSolution Architecture

Thank You!




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Oee on hana overall equipment effectiveness overview aug 2012 (2)

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