Eliminate manual data collection
OEE – Overall Equipment Effectiveness - is now universally recognised as an effective method of measurement, control and improvement of manufacturing efficiency.
PlantRun offers a complete software and hardware package to automate OEE data collection, processing and reporting and provide a range of benefits including;
- Eliminates the problems associated with manually collecting OEE information. Manual data collection is time consuming, disruptive to operations and inevitably leads to errors and omissions in the OEE data. The PlantRun system uses automatic data collection so staff time is not wasted gathering information. All downtime events are captured without the need for operator input.
- Fits to any make, type or age of asset – machines, production lines, work cells, even manual assembly. The PlantRun OEE system can connect to any type of production equipment - modern or legacy. Adaptors allow easy integration to PLCs, existing automation systems, sensors or manual input devices. It does not matter how old the equipment is or what controls it has. PlantRun can monitor OEE on any manufacturing asset.
- Gives you live real time OEE for improved manufacturing management. OEE information is presented in real time on boards, screens and mobile devices. Instant visibility of performance means issues can be identified and addressed straight away. With live data, actions are timely before small issues escalate into major inefficiencies.
- Information can be accessed anywhere on PC’s, tablets and smartphones. Authorised staff can view OEE data on any device - in the office, around the factory or even remotely. OEE information can be integrated into existing IT systems and ERP software to share key data across the business.
- Large screen KPI displays in production, rest and meeting areas inform and motivate staff. Digital signage displays show live OEE performance and other key metrics. They focus staff attention on efficiency and reinforce the importance the business places on driving up productivity.
- Alerts via SMS, email & public address ensure fast response to breakdowns and production disturbances. Alarms are triggered when machines go down or efficiency falls below target. Notifications go direct to staff that can take immediate corrective action and get production restored with minimum delay.
- Captures all downtime and all reasons for long stoppages. The system logs all downtime - both planned and unplanned. Staff can enter reasons for stoppages as they occur. This intelligence helps identify root causes of inefficiency and where to focus improvement efforts.
- Built in report and analysis tools identify where to target resources for best return. OEE reviews at machine, line, plant and company level quickly reveal strengths and weaknesses in current operations. Benchmarking identifies best practices that can be applied more widely. Data analysis steers capital and process improvement projects for optimal OEE gain.
- OEE daily performance. Day to day OEE is displayed on boards for each area and shows achievement against target. This maintains staff focus on efficiency and drives small incremental improvements that add up to large OEE gains over time. Public display charts progress and celebrates record breaking shifts.
PlantRun automated OEE monitoring has been proven in use in a wide range of manufacturing sectors confirming the system’s capabilities and benefits.
Our current users report a typical payback period of under 12 months. PlantRun costs just a fraction of new capital equipment so it makes sound financial sense to implement an OEE system to free up “hidden” capacity first. Increased throughput and reduced downtime lead to fast ROI.
For more information call on 01642 370666 to arrange an online demo and discuss how PlantRun can optimise OEE in your facility.
OEE Reference on Wikipedia
Overall Equipment Effectiveness (OEE) is a widely used metric in the manufacturing industry that helps to measure the performance of equipment or machinery. While OEE can provide valuable insights into a company's production efficiency, there are also several pain points that manufacturing companies may experience when using OEE as a metric. Some of these pain points include:
Lack of Standardisation: OEE is a metric that is calculated differently by different organisations, which can make it challenging to compare results and identify best practices.
OEE (Overall Equipment Effectiveness) is a crucial performance metric used by manufaturerss to measure the effectiveness and efficiency of their production processes. OEE provides a comprehensive view of how well equipment is performing, and it takes into account all factors that affect productivity, including availability, performance, and quality. In this article, we will answer some of the most frequently asked questions about OEE systems.
What is OEE and what does it measure?
OEE is a performance metric that measures the overall effectiveness of equipment used in production processes. It is a percentage that represents the amount of time equipment is available, the quality of the products produced, and the speed at which the equipment performs. OEE is calculated by multiplying the availability, performance, and quality of the equipment. OEE is a powerful tool that can help businesses identify areas of improvement in their production processes and increase productivity.
Implementing Overall Equipment Effectiveness (OEE) in manufacturing settings can come with various challenges. Here are some common challenges manufacturers may face during the implementation of OEE, along with potential solutions:
Lack of Data and Data Collection Challenges: One of the key challenges is often the availability and accuracy of data required for calculating OEE. Manufacturers may struggle with manual data collection processes, inconsistent data sources, or missing data points.
Solution: Implementing automated data collection systems, such as machine sensors or IoT devices, can streamline data collection and improve accuracy. Integrating equipment with data acquisition systems or manufacturing execution systems (MES) allows for real-time data monitoring, reducing manual data entry and enhancing data reliability.
Resistance to change and workforce engagement are critical aspects to consider when implementing Overall Equipment Effectiveness (OEE) in a manufacturing environment. Here's a more detailed exploration of these challenges and potential solutions:
Lack of Awareness and Understanding: Resistance to change often stems from a lack of awareness and understanding about the purpose, benefits, and mechanics of OEE. Employees may be unfamiliar with the concept or perceive it as an additional burden without understanding its potential positive impact.
Solution: Effective communication and education are key. Begin by clearly articulating the purpose of implementing OEE and how it aligns with the organisation's goals. Conduct training sessions to explain the fundamentals of OEE, its benefits, and how it can positively impact the workforce. Provide real-life examples and success stories to illustrate the potential improvements that can be achieved through OEE.
Implementing OEE Monitoring
When it comes to implementing an OEE monitoring system, manufacturers face the decision of choosing between cloud-based and on-premise PC-based systems. Each option has its own set of advantages and disadvantages that should be carefully considered based on the specific needs and circumstances of the manufacturing environment.