The key of the OEEm system is the “Centralized data distribution and processing center” aka. CDP.
This centralized software consists of two independent closed virtual machine. One of them is a windows based system and the other is a Linux based data and web-server.
The key function of the CDP is to collect all the production data and technical parameters that is necessary to analyze the manufacturing processes, directly from the manufacturing machines’ operating system or through a remote I/O data collector that is set up nearby these machines. Then the collected data is securely stored at a central database according to the parameters that were setup as default during the OEEm initial installation.
The CDP also maintain connection between the machine’s operator panels on which the manufacturing process can be monitored in real time, and the machine operator can input various pre-determined manufacturing and production details.
The collected and processed data then can be displayed on any of the manufacturing plant’s displays and monitors regardless of their size and location within the plant.
The production data is analyzed in a mobile compatible internal web-surface. This provides instant access even outside of the plant, so the management can be up-to-date on the current manufacturing production details.
This function helps to enter different manufacturing schedules and assign designated shifts for each schedule. Designating shifts is essential to be able to analyze the production based on shifts.
The system provides a surface to input basic product details for finished or in-progress products.
Then for each product different production steps can be associated and for each production step different machines can be linked. The most important parameter, the cycle time, is set up here.
Individual Product Identification is done via product specific bar codes attached to each product.
The manufacturing (parameters) are directly associated to each product, to help to satisfy the quality standards.
The system is capable to manage individual employees and assign them to work groups. Various levels of authorizations can be assigned to these work groups.
Idle time management helps to identify the source of non-productive machining time. The source type can be general for the entire fleet or specific for individual machines. By the utilization of the idle time management it is possible to identify the reason when a machine in the production line stops. In case of idle time, the information to be displayed can be customized based on user/ management or production preference. The machine operator can input the source of idle time directly. When production resumes, the system saves the information and the non-productive machining time. Then the operator can manually switch the display to show the production details again.
A specific product is linked to a production order. During production, the manufactured quantity can be checked at any time.
The system records all the parameters associated with specific production. These parameters can be customized and different for each machine.
The following parameters are recorded during Production Monitoring:
The operator panel is a multifunctional industrial panel PC with touch display to input and display various data. The panel is strategically placed close the machine operator for easy access.
The screen displays in real time production information such as, product name, ordered and completed product quantity.
One of the customization feature is the “product multiplication” function. This is a beneficial option for production lines that uses machines that manufacture multiple product in one step.
Another customization feature is the “multi-order” function. This is beneficial when multiple orders are done in one step on one machine.
With this feature the difference of the projected and actual cycle time can be monitored in real time.
With passive displays, production details and the status of the manufacturing machines can be displayed (shared) on independent screens.
The displayed information can even vary between screens, so different information can be displayed in different physical locations.
The reporting system provides capability to analyze previously recorded data. The system stores all parameters to help analyze productivity and production efficiency.
The reports can be viewed on a website that supports mobile devices, such as phones and tablets.
Non-compliance management (embedded in production)
The operator panel is directly attached to the production line to provide the surface for the operator to identify the manufactured product and record quality measurements. The non-compliance product source can be defined to different manufacturing machines independently, the can be selected during quality control.
In the report system under non-compliance module the ratio of compliance and non-compliance product ratio is readily available, per purchase order, shift or time frame
This measurement software was developed for specific tooling.
(Note: For OHAUS manufactured scales with EN-2 Ethernet Interface.)
At the weight station, products and parts are measured and stored with their associated weights.
It is capable to store serial numbers, with time stamp and expiration date. This function is best to utilize for example for glue machines to record the information for the glue used for the production.
Operators can directly log in to the system. All data is stored with the operator’s ID (identification). Operators efficiency and work hours can be analyzed.
The system is flexible, one operator can log in to multiple machines (in case one operator runs multiple machines); or multiple operators can log into one machine (in case one machine is run by different operators).
This not only gives the access to monitor and analyze the efficiency of the machine operator, but also provides a tool to measure the maintenance crew repair time in the event of a machine breaks down.
For example, before any repair would be done, the maintenance personnel logs in to the system, and logs out once the repair is completed. Future maintenance time can be projected based on the historical maintenance time in the system.
Supervisors and maintenance crew have access to real time status report of the machines. They have quick and efficient way to access product quantity, idle time and possible break downs.