These are our efficiency modules: Andon (real time monitoring) and OEE (Overall Equipment Effectiveness) for a periodic check of efficiency

1. IMPROVE: THE EFFICIENCY IN THE PRODUCTION LINE
ANDON, HOW IT WORKS | ARCHITECTURE | THE OEE CALCULATION
1

2. IMPROVE| The efficiency modules
Improve is a Web-Oriented and Agent-Based system, focused on
monitoring and improvement of industrial processes, that
belongs to the class of MES system (Manufacturing Execution
System).
In this presentation, we will discuss the efficiency modules:
Andon and OEE.
2

3. Functional analysis | Andon
• What do we need?
A LED TV
A touch screen
A barcode reAder
A PLC
• Where?
In the production line
3

4. Andon board: data from the LED TV
4

5. Andon board: the 7’’ touch screen
5

6. Functional analysis | In the office
• Real time control
• The process owner can control,
from his office, the production
performance of each production
line
• Periodic check (OEE calculation)
• The process owner can verify the
production trend hour by hour
6

7. Real time control of the production lines
7

8. Periodic check of the production line (OEE)
8
Details

9. The architecture | How we get the data
9
ERP IMPROVE
RFC
Line 1 Line 2 Line n. PLC
Monitor
Touch screen
Monitor
Touch screen
Monitor
Touch screen
Ethernet
Office

10. The architecture | Data gathered
• The Andon system is aimed to quantify the following data :
• Counting pieces: the ERP communicates to Improve the pieces tested. The
operator, through a barcode reader, communicates to Improve the serial
number of the single piece. On robotic systems, this data is gathered by a PLC.
• Counting stops: the operator communicates to Improve the number of stops
using a touch screen device. On robotic systems, this data is gathered by a PLC.
• Counting scrap items: the operator communicates to Improve, the number of
anomalies using a touch screen device. On robotic systems, this data is
gathered by a PLC.
• Start and finish of the setup: the operator communicates to Improve the start
and the finish of the setup using a touch screen device.
10

11. The architecture | Counting pieces
11
ERP
RFC
Serial number
PLC
Serial number
Scanner barcode
Counting pieces
Tested pieces
IMPROVE

12. 12
Ethernet
HMI interface
Start/end stop
and his cause
Counting stops and their causes
PLC
Start/end stop
and his causeIMPROVE
The architecture | Counting stops and their causes

13. The architecture | Counting scrap items
13
Ethernet
Counting scrap items
PLC
Scrap items
IMPROVEHMI interface
Scrap items

14. The architecture | Setup
14
Ethernet
Start and finish of the setup
PLC
Setup
IMPROVEHMI interface
Setup

15. OEE | How to calculate
• The OEE calculation allows to identify and quantify the major production
losses of plant and monitor the efficiency of production processes.
• For each plant, OEE correlates real output with the ideal production
planned.
• The difference between these two values represents the loss of
production in terms of:
RF = Availability (Time)
RV = Performance (Speed)
RQ = Quality
• The OEE is simplified in the multiplication of the indexes described above,
then : OEE = RF * RV * RQ
15

16. OEE | Step by step (1/3)
• Improve, software developed by NeXT, interfaces with the ERP asking the
production order data.
• The ERP then returns the following data:
• Production order
• Model code
• Quantity
• Standard Cycle Time
• Numbers of workers
16

17. OEE | Step by step (2/3)
• Improve transfers the production order’s data to its database and puts
them in relation with the data coming from the field (from the operator or
from the PLC).
• Improve, for each production order, is able to obtain:
• Number of pieces produced;
• Number of stops;
• Number of scrap items;
• Takt-time
17

18. OEE | Step by step (3/3)
• Now we are able to calculate the three variables : RF (Time availability); RV
(Speed performance); RQ (Quality). We can also calculate the OEE, which
is equal to RFxRVxRQ.
• Let's see how you get these three variables:
18
RF =
d-f
d
RV =
Tc*Np
(d-f)
RQ =
Np-Nc
Np
Where d = time availability; f = stops; Tc = cycle time; Np = Number of pieces
Nc = non-compliance

19. OEE | Step by step (scheme)
19
IMPROVE ERP
Data request
Prod. order, model code, quantity,
Standard Cycle Time, n. workers
Database
N. Pieces
N. Stops
N. Scrap items
Takt-time
Foreachproductionorder
OEE

20. OEE | Summary (1/2)
• The Improve system, developed by Next, is able to gather data from ERP
systems (SAP, etc. ..)
• Improve communicates with the ERP to take the necessary data both for
Andon and OEE efficiency.
• Improve is not limited to providing the data OEE, but highlights where
there are losses that do not permit the construction of an OEE of 100%, as
shown in the following slide.
20

21. OEE | Summary (2/2)
21
From these histograms, we can see how
the blue detailing the losses related to
the speed; red for the losses stops;
yellow for losses regarding quality
(absent in this example). The green is the
OEE efficiency.
Once known these data, you have all the
information needed to operate in the
perspective of the continuous
improvement.

22. OEE | NeXT
22
Elica
Traceability of the
product unit in all
Italians and foreign
factories.
Quality control
based on vibrational
and noise analysis
(VibCo)
Franke Group
Andon monitoring
on production line
Overall Equipment
Effectiveness (OEE)
Faber
Andon monitoring
on production line
Overall Equipment
Effectiveness (OEE)
Quality control
based on vibrational
and noise analysis
(VibCo)
Ariston
Thermo
Overall Equipment
Effectiveness (OEE)
WCM support
through the "just in
time" in production
lines
SCA Hygiene
Products
Statistical Proces
Control
Warehouse
management
Monitoraggio di
consumi e relativi
costi di chimici e
fattori energetici
rapportati alla
produzione
FCA Group
Managing assembly
of engines in the
finishing department
with pick-to-light
Control of plant’s
AGV
Andon monitoring
on production line
Enel
Distribuzione
Design and
mechanical
verification of
medium and low
voltage power lines
in compliance
NeXT is a software house that produces and markets informatic systems designed to provide information and
aggregated data to the corporate management, supporting it in its operative decisions.
Best Next references