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KPI/Metrics for the process industry
Charlotta Johnsson
A company is considered a Business Mover
if it has improved:
a) More than 10% on one or many of the financial metrics
b) More than 1% on over half of the financialmetrics
From: MESA survey ”Metrics that Matter”, Oct 2006.
Typical for Business Movers is that they:
1) Have well defined KPIs
2) Have informed employees
3) use IT systems to get measurements, calculate Key Performance Indicators (KPIs,
Metrics) and display the results.
From: MESA survey ”Metrics that Matter”, Oct 2006
KPI/Metrics for the process industry
Charlotta Johnsson
CHALLENGES:1) What key performance indicators are used in process industry today?2) Do the key performance indicators differ depending on company characteristics?3) How can key performance indicators be exchanged between differentsoftware-applications?
PROJECT:• PiiA financed project (jan2015-dec2016) called “PiiA-Metrics”
Inte
gratedin
form
ation
han
dlim
g
ManufacturingOperations Management
Control System
Business System
Key performance indicators (KPIs) are metrics designedto visualize, assess, and manage the performance ofspecific operations within enterprises.
What is a KPI?
Performance Management:
1. Awareness of current situation
2. Clear view of the desired situation
3. Improvement potentials
4. Improvement
Functional Model of an Enterprise (ISA95)
6
Level 4
Level 1
Level 2
Level 3
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations ManagementDispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
DiscreteControl
1 - Sensing the production process, manipulating the production process
2 - Monitoring, supervisory control and automated control of the production process
3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.
Time FrameShifts, hours, minutes, seconds
4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels.
Time FrameMonths, weeks, days, shifts
Level 0 0 - The physical production process
ContinuousControl
BatchControl
Level 5Company Management
5 - Receive sales orders, assure shipping and customer relations.
Time FrameYears, Months
9/16/2015
ISA 95 – Activity Model for Production Operations
Productiondatacollection
Productionexecutionmanagement
Productionresourcemanagement
Productiondispatching
Productiontracking
Detailedproductionscheduling
Productdefinitionmanagement
Level 1-2 Process Control
Productionperformanceanalysis
Equipment and processspecific production rules
Operationalcommands
Operationalresponses
Equipment and processspecific data
Level 3
Level 4 Business Planning & Logistics
Product Definition
Production Capability
Production Schedule
Production Performance
Level 4
Level 1-2
Earlier work
ISO 22400 is an international standard• Lists 34 commonly used KPIs• Standard released in 2014• Used today in e.g. MES-
product development
Source: ISO 22400 – Part1 (2014)
KPI definition
Content:
Name
ID
Description
Scope
Formula
Unit of measure
Range
Trend
Context:
Timing
Audience
Productionmethodology
Effect modeldiagram
Notes
1: What KPIs are used today?
1: What KPIs are used today?
1: What KPIs are used today?
1: What KPIs are used today?
Include KPIs used in Process Industry
• Find commonly used KPIs in PI• Interviews with companies (5 signed up)• Describe KPIs according to table-structure• Other findings
2: Do the KPIs differ depending on company characteristics
Company characteristics:• Continuous (CO) vs Discrete Object (DO)• Speculation (SD), Hybrid (HD) or Customer-order Driven (CD)• Continuous (CM), Intermitent (IM) or One-time Mode (OM)
3: How can KPIs be exchanged?
KPI definition
KPI definition property
KPI instance
KPI instanceproperty
KPI value
KPI rangeKPI resource
reference
0…N 0…N
0…N1 1 0…N
0…N 0…N
UML models are used to define the structure of a KPI
UML is an implementation independent specification format.
3: How can KPIs be exchanged?UML models are used to define the structure of a KPI
class KPI Object Model
KPI Definition
+ ID
+ Name [0..1]
+ Description [0..*]
+ Scope [0..*]
+ Formula [0..1]
+ UnitOfMeasure [0..1]
+ Trend [0..1]
+ Timimg [0..1]
+ Audience [0..*]
+ ProductionMethodology [0..*]
+ EffectModel [0..*]
+ Notes [0..*]
KPI Value
+ ID
+ Description [0..*]
+ Name [0..1]
+ Value [0..1]
+ UnitOfMeasure [0..1]
KPI Definition
Property
+ ID
+ Description [0..*]
+ Value
KPI Instance Property
+ ID
+ Description [0..*]
+ Value
KPI Value Property
+ ID
+ Description [0..*]
+ Value
Resource Reference
+ ID
+ Description [0..*]
+ ResourceType
+ ResourceID
KPI Range
+ ID
+ Description [0..*]
+ LowerLimit
+ UpperLimit
KPI Instance
+ ID
+ Description [0..*]
+ Name [0..1]
+ Scope [0..*]
+ Formula [0..1]
+ UnitOfMeasure [0..1]
+ Trend [0..1]
+ Timimg [0..*]
+ Audience [0..*]
+ ProductionMethodology [0..*]
+ EffectModel [0..*]
+ Notes [0..*]
KPI Definition Time
Range
+ StartTime [0..1]
+ EndTime [0..1]
+ Recurrence [0..1]
+ Duration [0..1]
KPI Instance Time
Range
+ StartTime [0..1]
+ EndTime [0..1]
+ Recurrence [0..1]
+ Duration [0..1]
KPI Value Time Range
+ StartTime [0..1]
+ EndTime
+ Recurrence [0..1]
+ Duration [0..1]
0..* 0..10..* 0..*0..* 0..*
1
+is defined in
0..*1
+is defined by
0..*
0..*
0..*
0..*
0..*0..*
0..*0..*
+may be used in
calculation of 0..*
0..*
+may be used in
calculation of 0..*
0..*
3: How can KPIs be exchanged?
KPI definition
KPI definition property
KPI instance
KPI instanceproperty
KPI value
KPI rangeKPI
resourcereference
0…N 0…N
0…N1 1 0…N
0…N 0…N
UML models define the KPI structure
Information
Provider
Information
Requestor GetKPIDefinition
ShowKPIDefinition
UML models are translated to XML schemasXML schemas can be exchanged between various systems
UML model: a software independent representation of the information to be exchanged
3: How can KPIs be exchanged?
Exchanging KPIs
XML schemas for KPIs, an implementation proposal for the information to be exchanged
<KPIDefinition><ID> </ID><Description> </Description><Name> </Name><Scope> </Scope><Formula> </Formula><UnitOfMeasure> </UnitOfMeasure><Range>
<ID> </ID><Description> </Description><LowerLimit> </LowerLimit><UpperLimit> </UpperLimit>
</Range><Trend> </Trend><Timing> </Timing><Audience> </Audience><ProductionMeth.> </ProductionMeth.><Notes> </Notes>”
</KPIDefinition>
3: How can KPIs be exchanged?
XML schemas are refered to as KPI-ML
KPI-ML was released by MESA, May 2015
Available at MESAs homepage www.mesa.org
KPI/Metrics for the process industry
Charlotta Johnsson
CHALLENGES:1) What KPIs are used in process industry today?2) Do the KPIs differ depending on company characteristics?3) How can KPIs be exchanged between different software-applications?
OTHER topics: navigation among KPIs, finding target-values to the KPIs, KPI lifecycle management.RELATED TO: active participation in ISO22400 and MESA
PROJECT:• PiiA financed project (jan2015-dec2016) called “PiiA-Metrics”
KPI/Metrics for the process industry
Charlotta Johnsson
CHALLENGES:1) What KPIs are used in process industry today?2) Do the KPIs differ depending on company characteristics?3) How can KPIs be exchanged between different software-applications?
OTHER topics: navigation among KPIs, visualization, finding target-values to the KPIs, KPI lifecycle management.RELATED TO: active participation in ISO22400 and MESA
PROJECT:• PiiA financed project (jan2015-dec2016) called “PiiA-Metrics”
23
The following 34 KPIs are defined in ISO 22400 – Part 2
KPIs defined
6.1 Worker Efficiency6.2. Allocation Ratio6.3. Throughput rate6.4. Allocation efficiency6.5 Utilization efficiency6.6. Overall equipment effectiveness index6.7 Net equipment effectiveness index6.8 Availability6.9 Effectiveness6.10 Quality Ratio6.11 Setup Rate6.12 Technical efficiency6.13 Production process ratio6.14 Actual to planned scrap ratio6.15 First pass yield6.16 Scrap ratio6.17 Rework ratio
24
The following 34 KPIs are defined in ISO 22400 – Part 2
KPIs defined
6.18 Fall off ratio6.19. Machine capability index6.20 Critical machine capability index6.21 Process capability index6.22 Critical process capability index6.23 Comprehensive energy consumption6.24 Inventory turns6.25 Finished goods ratio6.26 Integrated goods ratio6.27 Production loss ratio6.28 Storage and transportation loss ratio6.29 Other loss ratio6.30 Equipment load ratio6.31 Mean operating time between failures6.32 Mean time to failure6.33 Mean time to restoration6.34 Corrective maintenance ratio
Functional Model – NNE Example
HistorianSystem
Finance Management
Production Management
Maintenance Management
Learning & Training
Quality Management
Electronic Document
Management
LaboratoryManagement
MESSpec
Management
MESResource
Management
MESPlanning & Scheduling
MESExecution
MESData
Collection
MESAnalysis
MESTracking
BMS System PEMS System DCS System SCADA System
PLCSystem
PATSystem
Q
PRISM
S9
5 L
evel
2S
95
Level
3S
95
Level
4
Process Industry
• Pulp & paper
• Chemicals and plastics
• Petroleum
• Pharmaceutical
• Mining
• Iron and Steel
• Food
Source: IVA 2006