OEE DATASHEET | Idhammar OEE Reporting

IDHAMMAR OEE REPORTING MODULES deliver a full suite of clear, accurate, and real-time reports against key performance metrics, enabling users to implement timely and effective loss management strategies. With extensive drill-down capability and alerts to accelerate response times to performance recovery, users from the shop floor to the boardroom can achieve greater control of the daily management of the plant - at group level, division, site, line, and key asset.

Accurately measuring performance and automating reporting Having an industry standard measurement in place to gauge how well you’re performing is important, but it’s what improvement teams do with the information, and how quickly they can execute counter measures to issues, that really counts. Idhammar OEE Reporting modules ensure the entire team will be working towards accelerating manufacturing and maintenance response times to failures and recovery.

The Idhammar OEE Reporting modules all have easy to interpret graphical user interfaces and report a range of key metrics in user-friendly formats.

Flexible standard reporting tailored to your production environmentThe standard Idhammar OEE System reporting capability includes highly flexible, user-defined fields such as production areas, asset hierarchy, failure events, process data and products, ensuring the information generated is specific to your production environment. ‘What If’ analysis filters can be used to analyse individual lines, product categories, events, shifts, and trends, in order to study the impact of eliminating known production problems.

Idhammar OEE Reporting– Keeping the entire team focussed on improving

IDHAMMAR SYSTEMS – keeping industry moving and improving

Fig 1. What-if Analysis: what happens to the OEE score when glue-unit fail-ures are filtered out?

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User defined reporting is available in addition to a wide range of specified graph and text reports, providing up to the minute performance metrics at the touch of a button. Some of the most popular reports within the range of over fifty standard reports on offer include:

• OEEscorewithelementalbreakdown-Availability,Performance,Quality

• Set-upandshiftperformance

• DowntimebyEventsorTimeshowingnumberoffailuresand/orminuteslost

• DowntimeasaPercentageofOperatingTime

• ProductivitybasedonLinemanninglevels

• Costofdowntimeandwasteascashvalues

• WorsteventsforaselectedDate,Time,orEntityrange

• MTBFandMTTRshowingtheaveragetimebetweenfailuresandrepairtimes

• Real-timeunitproduction,viewedbyEntity,Time,Dateetc.

• Whatif’analysis–calculatedasanOEEimprovementpercentage

• ‘BestofBest’-whatcouldbeachievedbasedonhighestvaluepointsatdifferenttimes

• IncreasedUnits-theextraunitswhichcouldbeproducedwitheach1%OEEimprovement

These reports are particularly useful for Continuous Improvement teams as they enabledetailed trend analysis which can be applied to loss management strategies, whereas shop-floor OEE Dashboards provide operators with an ‘at-a-glance’ view of their shift progress.

OEE Dashboards providing real-time operational intelligenceIdhammar’s OEE Dashboard software has been specifically designed to provide company-wide display of KPIs, delivering the platform for organisations to:

• Engage staff, ensuring that all stakeholders are clear on performance versus target

• Increase efficiency by quickly identifying and responding to exceptions

• Support continuous improvement by highlighting lost opportunities

Idhammar OEE Dashboards are configured to show the data that is important to shop-floor operators,andshowtheperformanceagainstmetric(KPI)foraspecificroleand/orjobhold-er. Users are able to drill-down to a desired level of detail, and set alert thresholds or assign themselves tasks - without requiring IT support to do so. Team leaders and management are empowered to identify individual losses and trends.

OEE Dashboard displays can be broadcast to plasma screens, providing greater visibility across the wider organisation. This can have a beneficial effect on team-work and support cross-functional communication.

With operations data available at the touch of a button, Idhammar OEE eliminates the need to spend time manipulating data, thus releasing staff to focus on the Improvement Agenda.

Fig 2. Example of an OEE Dashboard displaying OEE by line.

Fully integrated Improvement Agenda for Accountability and ActionIdhammar OEE’s unique fully integrated Improvement Agenda provides a foundation for essential lossmanagementstrategies.The ImprovementAgendahelps tostructureobjec-tives and steps with flags to plan, monitor, and encourage progress.

Best-practice‘Accountability’process(measure,prioritise,allocate,resolve)istoreviewthe‘Top 5’ losses and assign each of them to the individual best able to deliver a resolution. Each time a review session identifies what needs to be done, the tasks are recorded as an Improvement Agenda item. Figures for the costs and savings of resolving the loss can be included along with target completion and review dates, so that progress is tracked and recorded accurately.

WhilsttheCIteamsandFLMsneedtoseetheOEEandlossdetails,moreseniormanagerscansimply review the improvement traffic lights to ensure that teams are making progress and are on target. More importantly, they can check to see if there are any significant production losses that have not been addressed, so that no opportunities to recover losses are missed.

Andon Displays that send motivational real-time signals to the team The ‘Andon’ signalling concept originated in Japan as a line stop cord and has since evolved to become a highly useful communication tool in the manufacturing environment. Placed at the end of the production line, Idhammar OEE Andon Display boards provide real-time line-specific KPIs and direct messages. Andon Displays are highly visible motivational tools to alert the entire team to problems on the line that may impact the shift’s schedule. Whilst operators may already be aware of problems, there will also be implications for materials handlers, changeover teams, hygiene, and customers. Opening lines of communication throughout large plants is essential to ensure that staff in supporting or feeder areas are aware of progress across their dependent lines.

Configurabletoyouroperation,typicaldisplaymetricsofteninclude:

• OEESCOREsnapshotandavaluefortheA,P,andQelementsfortoday/thisshiftetc.

• CHANGEOVERFREQUENCYandTIMEwithactualtimesandtargets

• WASTEQUANTITY/PERCENTAGEandENERGYCOUNTifwasteisaproblemintheplant

• DOWNTIMETHISSHIFTwithTop5Issuesforoperatorsandmaintenanceteams

When the line comes to a complete stop, or there is a period of prolonged slow running, a total count of lost time and the stoppage reason are communicated via the Andon Display – focusing the team’s effort on getting the line back up to speed as fast as possible.

Idhammar Systems will help users ensure the information fed through the Andon Display is relevant and useful, in order to inform and motivate staff. Andon displays work most effec-tivelywhenusedinconjunctionwithothercommunicationspoints,alertingkeyoperatorstocheckTouchScreenUnitsandtriggeringBusinessAlertstomobilephonesande-mailtokeep relevant managers informed of critical issues.

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Fig 3. Improvement Agenda used to drive change.

Fig 4-6. Andon Displays used to alert team to production issues.

Idhammar Systems Limited | Buchanan’sWharfSouth,FerryStreet,BristolBS16HJ,UnitedKingdomTel: +44(0)117 9209400 Email: info@idhammarsystems.com www.idhammarsystems.com

Copyright © 2011 Idhammar Systems Ltd.

All rights reserved. July 2011

OEEBusinessAlertsthatenablerapidandinformeddecision-makingIdhammarBusinessAlertsworkinconjunctionwiththeImprovementAgenda,Dashboards,andAndonDisplays,anddirectlylinksyourCMMSwithyourOEEsystemstoaccelerateengi-neeringresponsetimestomaintenance,manufacturing,andproduction issues. BusinessAlerts automate the escalation process, ensuring that relevant people are involved with rectifying problems, and notifying different levels of management as appropriate to the severity and time taken to resolve delays to production.

Any predefined exception criteria can trigger an alert; waste above a certain level, down-time for the shift over 30 minutes, ‘short order’ position, throughput below target etc. Whererequired,aWorksOrdercanalsobeautomaticallysenttoaCMMS,preventinganycritical issues being missed during equipment down-time, and ensuring the task becomes part of the maintenance planning process and does not get overlooked in shift handovers.

Business Alerts can be communicated via SMS, e-mail and/or Dashboards and AndonDisplays, depending on the requirement to alert private, public or user defined group.

Productivity ReportingProductivity, or ‘Labour Recovery’ reporting enables the comparison of actual labour used within the process, with the established target crew size. Labour rates can be set for dif-ferent skills levels so the reports provide an accurate Overall Labour Effectiveness score or OLE. Used with Idhammar Systems’ data capture solution, the module allows crew numbers toberecordedastheproductionrunstarts,andalsoadjustsasnecessaryduringtherun.Reports include labour cost by asset, shift, product, and work order. The ability to identify the labour cost, per product made, adds a powerful extra dimension to the OEE measure.

Reporting HardwareIdhammar Systems works with a range of selected hardware suppliers to deliver each of the solution options. Equally, if reporting hardware such as plasma screens and Touch Screens Units are already available within the organisation, Idhammar Systems’ experienced techni-cal team can configure the software and signal feeds to work with the hardware and max-imise the return on your existing IT investments.

ComplementaryProductsTheIdhammarOEEReportingmodulesworkinconjunctionwiththeIdhammarOEESystemwhich is future proof and fully upgradeable with a range of complementary products from Idhammar, including:

OEE Line Data Portal - data capture solutions for manual and automated environments.

OEEQualityMonitor-for paperless control of compliance and reporting.

OEE Energy Monitor - for full visibility of energy consumption and efficiency.

Idhammar MMS - for the efficient management of all maintenance operations

Separate product datasheets are available via the website: www.idhammarsystems.com/resourcelibrary

For more information on how the Idhammar OEE Reporting modules can support your con-tinuous improvement programmes:

Call:+44 (0)117 9209400 Email: info@idhammarsystems.com orVisit:www.idhammarsystems.com

Fig7-8.BusinessAlert(WorkOrder)sent by e-mail, SMS, Dashboards or Andon Displays .