Machinery performance analysis maximises OEE

Edited by the Engineeringtalk editorial team Dec 21, 2004

A new discrete machine performance solution allows manufacturers to quickly and cost effectively measure and improve the operating equipment effectiveness (OEE) of machinery.

A new discrete machine performance solution comprises a preconfigured package of hardware, software and engineering that allows manufacturers to quickly and cost effectively measure and improve the operating equipment effectiveness (OEE) of machinery.

The DMP discrete machine performance solution includes a robust industrial PC loaded with Rockwell Software RSBizWare designed to automatically gather real-time manufacturing data and turn them into instantly useable information.

This enables the performance of machinery to be analysed in real time to solve the problems causing lost production at the time rather than just report them at the end of the shift.

The DMP package includes configuration and user training by an experienced Rockwell Automation engineer, so for a fixed cost users can be certain the system will produce valuable reports straight out of the box.

The DMP is able to help resolve a wide range of common factors that can drag down OEE scores, including: persistent problem with one machine; difficulty identifying the root cause of downtime; pressing need to monitor and analyse productivity; breakdown reasons are not recorded consistently; manual log of events does not provide enough information; data available in the PLC are not complete and data collected manually are not reliable; and efficiency and downtimes reports are not available online.

The DMP can collect data at an individual machine or from up to a maximum of five machines allowing detailed analysis of the root causes of downtime.

A machine's overall OEE score measures the actual output of good quality product compared with its theoretical maximum output.

OEE is affected by a combination of factors including operating time, machine availability, performance and product quality, and real-time data on all events affecting output must be collected to get a full and accurate picture.

The DMP has built-in drivers allowing it to gather data direct from most modern Allen-Bradley or third party OPC-based PLCs, from Scada systems and from operators via the HMI using preset codes to enter reasons for machine stoppages.

These data are compiled in a database for instant statistical analysis, and reported in over 40 standard report formats that allow the major causes of downtime to be identified and eliminated.

As a standard, configurable solution, the DMP is up to 10 times faster to install and set up than a custom-built data collection and analysis system.

Short training courses are also available from Rockwell Automation to provide engineers with all the skills needed to reconfigure RSBizWare to produce reports specific to their application.

Reports can be viewed locally on the DMP or company intranet, posted on the Internet as secure web pages for remote viewing and displayed on large screens on the factory floor so they can be seen and acted on by management and operatives.

By using the DMP to help raise OEE scores from typical levels of 30-40% to world-class 90%-plus, manufacturers can increase capacity without investing in additional plant and improve returns on their existing assets.

Return on investment (ROI) can also be calculated, enabling manufacturers to determine if a machine is producing the expected profitability.

Because the DMP works with accurate data it enables both manufacturers and OEMs to check that a newly installed machine is delivering the output set out in the original specification.

Any deviation from the specified production capacity can be investigated and corrected so that the machine delivers the promised output.

The DMP is portable and when problems have resolved on one machine it can be easily transferred to another to steadily improve performance across an entire production line or factory.

The DMP discrete machine performance solution from Rockwell Automation provides a complete, fixed cost system for analysing and reporting the major causes of lost production, boosting productivity and enabling rapid improvements in OEE and ROI to be made.