OEE-Designer

Overview

The Point85 Overall Equipment Effectiveness (OEE) applications enable:

Sources of equipment availability, performance and quality event data include:

The Point85 applications supporting OEE are:

In addition, two GUI test applications assist in the development of an OEE solution:

For more information about the Designer and other OEE applications, please refer to the Point85 OEE User Guide in the docs folder. A getting started tutorial, Point85 OEE Getting Started Guide, is also available in the docs folder. In addition, a document in this folder titled PackML and Point85 OEE describes a possible implementation the Point85 Overall Equipment Effectiveness (OEE) solution for equipment with a PackML interface.

OEE Calculations

OEE is the product of equipment availability, performance and quality each expressed as a percentage. The time-loss model is used to accumulate time in loss categories (or “no loss” if the equipment is running normally). A data source provides an input value to a data collector’s resolver JavaScript function that maps that input value to an output value (reason or production count).

For availability and performance, the output value is a reason that is assigned to one of the following loss categories:

For quality or yield, the data source provides a production count in the good, reject/rework or startup & yield categories in the defined units of measure for the material being produced. This count has an equivalent time loss calculation by using the defined ideal or nominal speed.

Architecture

The OEE applications can be grouped into design-time and run-time. The design-time Designer application is used to define the plant equipment, data sources, event resolution scripts, manufacturing work schedule, availability reasons, produced materials and units of measure for data collectors. The designer also includes a dashboard and trending capabilities.

An automated run-time data collector receives an input value from a data source source and executes a JavaScript resolver on this input to calculate an output value. The output value is a reason (mapped to an OEE loss category) for an availability event, a new production count (good, reject/rework or startup) for performance and quality events or a material/job change event. For the case of a custom event, the output value is ignored. The event data is stored in a relational database where it is available for OEE calculations. Microsoft SQL Server, Oracle, MySQL, PostgresQL and HSQLDB are currently supported.

A web-based manual data collector running in a web server records the OEE events based on information entered by an operator. Similar to the automated collector, this data is also stored in the relational database. If the system is configured for messaging, the event data is also sent to a RabbitMQ message broker to which a run-time monitor application can subscribe. A monitor displays a dashboard for viewing equipment OEE events. It also displays collector notifications and status information.

Designer Application

The Designer is focused on configuring all aspects of equipment in order to enable OEE calculations. It has editors for defining the plant model. For example, the plant entity editor is: Plant Entity Editor

The Designer has a trending capability to observe the input and output values of a configured data source. For example, an OPC DA variable trend is: OPC DA Trend

Collector Application

The Collector application runs as a Windows service or Unix daemon on the configured host computer. A Collector executes equipment event resolver scripts upon receipt of an input value and stores the availability, production, material or job change event data in the database. This data is used for OEE calculations.

Monitor Application

The Monitor application has three main functions, to observe:

An example of dashboard tiles is: Dashboard

Production and availability events can be shown in chronological order, for example: Dashboard Trend

Production and availability events can also be shown in a trend chart, for example: Dashboard Trend

The time-losses tab shows a bar chart of the OEE loss categories: Time Losses

A first-level Pareto chart show the time losses in percentage terms, for example: First Level Pareto

A second-level Pareto displays the reasons for an availability category, for example: Second Level Pareto

Operator Application

The Operator application is a desktop application that allows a user to enter availability, performance, production, material change and job events. The events can be recorded in chronological order as they happened or in summary form over a period of time by duration of the event.

For example, the screen for entering a reject production event is: Operator Production

Operator Web Application

The Operator web application is browser-based and allows a user to enter availability, performance, production, material change and job events. The events can be recorded in chronological order as they happened or in summary form over a period of time by duration of event.

For example, the screen for entering a summarized availability is: Operator Web Availability

Localization

All applications with user-visible text use resource bundles for localization. The locale is the default locale of the desktop or web server machine. Each application has two default resource bundles, one for text named (app name)Lang.properties and one for errors/exceptions named (app name)Error.properties with US English text.

Database

The Java Persistence 2.2 API (JPA) as implemented by the Hibernate ORM framework together with the Hikari connection pool is used to persist OEE information to the database. Hibernate and JPA abstract-away database specific aspects of inserting, updating, reading and deleting records in the tables. The API is designed to work with any relational database supported by Hibernate.

What's New

In version 2.6.0, cron job support was added. A job has a cron expression as triggered by the Quartz scheduler. The job executes a resolver script.