Downtimes are organized into time categories. Each company can use their own time categories: failure time, waiting time, setup time, pause etc. DataLyzer allows the creation of your own time categories, however, to ensure the proper calculation of OEE, these time categories would be mapped to one of the Loss types i.e. planned downtime, unplanned downtime, performance loss or quality loss.
Data can be collected manually by operators: downtime, causes and production data. Data can also be collected automatically from PLC, database or sensors depending on what information these machines can generate. The missing information required to calculate the OEE can be filled in at a later time.
Different roles with a different set of privileges allowing access to different parts of the DataLyzer OEE can be created. Users can then be assigned to these roles, thereby restricting the access to users. Eg Operators can be created to only enter downtime information without access to the Setup and the reports. Executive Staff can be given access only to the Reports.
DataLyzer allows the creation of up to 5000 different causes per machine allowing the flexibility to assign downtime causes per machine. This will ensure that the operators select from a predefined list. DataLyzer can also allow operators or engineers to change the cause after the root cause of the downtime is determined.
Machines can be grouped together and assigned to a specific schedule. A schedule can have predefined shifts for the week. Multiple schedules can be used simultaneously.
Since the schedules are assigned to machines, DataLyzer will automatically calculate the losses at the end of the shift. When a product is changed the run results will be calculated automatically. The losses per shift or run are also recorded in a Control Chart. This gives a better indication when something has changed from normal operations.
Machines rates for different products can be different on different machines. DataLyzer allows setting machine rates for different product/machine combinations. Operators can simply use Datalyzer to select a product or change a product for machines and the calculations are automatically performed for the finished production run
Besides the standard set of reports included OEE and Pareto charts, Mean time between failure (MTBF), Mean time to repair (MTTR), DataLyzer offers unlimited possibilities to generate reports using the OLAP reporting tool that works similar to the Excel Pivoting feature. Reports can be defined by drag-n-drop data fields into row or columns, set filters and ∑ like summations like sum, average, count, SD, variance and so on.
The unique feature of DataLyzer OEE is that it allows you to analyze OEE production data using SPC tools. Eg Downtime is automatically recorded on attribute control charts, that will help you analyze variation in downtime and remove special causes of variation to thus have a stable and predictable variation per machine. Similarly, quality defects per shift or run can be recorded on control charts thus simplify the data collection and enabling SPC tools on quality defects per product.
When problems require follow up you need to start corrective and preventive actions (CAPA). OEE integrates with the DataLyzer CAPA system.
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OEE is often implemented in 3 phases. First we start manually at the end of a shift or run using the DataLyzer SPC software. During the second phase the customer uses real time OEE to enter the downtimes immediately in the real time OEE module. In the third phase data is taken automatically from sensors or from the machine. The 2 movies below show examples of the first and second phase.
The video below shows how SPC and OEE is implemented in AFA Dispensing group