PROCESS IMPROVEMENT
of the natural human tendency to capture everything “just in case,” especially if it is easy and cheap to collect. How is this a problem? “It is waste,” he said. “It creates a muddled mess that makes it diffi cult to identify the real issues. So collect less data, do it really well, and then use that data to make deci- sions. Data is only so valu- able as how it’s used!” The context of OEE
measurement also matters. High-volume manufactur- ing processes can naturally have long production runs with very short cycles and few changeovers, and therefore a high OEE. By contrast a low-volume manufacturing process may have very short production runs with many change- overs, and therefore a low OEE. “Lacking context,
data using a variety of standards such as SQL, Ethernet and OPC. The company released its fi rst OEE module in 2011. “We are going to upgrade our OEE module this year and we have been receiving all kinds of input on it since 2011,” said Tom Hechtman, president of Inductive.
Vorne Industries manufactures the XL Productivity Appliance, a bolt-on hardware solution that calculates and displays OEE in real time on the factory fl oor.
OEE does not have value and can drive organizations to focus on the wrong things, such as over-production, or over- spending on labor to achieve a high OEE,” said Moran. Vorne Industries manufactures the XL Productivity Appli- ance, a bolt-on hardware solution that calculates and dis- plays OEE in real time on the factory fl oor. With over 16,000 installations across 40 countries, Vorne targets small-to medium-sized businesses that are currently capturing pro- duction information on pieces of paper, Excel spreadsheets, and in-house systems. Vorne designed the XL Productivity Appliance to be easily installed in almost any manufacturing process by a union- level trained electrician. “My customers want equipment that can measure OEE on existing and legacy equipment, and they usually have a mix of different machines from different suppliers,” he said. “That is why we provide a complete hard- ware and software system that is simple and easy to install.”
Variety, OEE and TEEP For providers of software and systems that calculate OEE, variety is its own complexity. The makers of the Ignition soft- ware package, Inductive Automation (Folsom, CA), seem to welcome variety. They help customers that include waste wa- ter, oil & gas, automotive, and general manufacturing. Ignition is positioned as an MES platform able to collect and connect
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AdvancedManufacturing.org | September 2016 One production scenario that he sees as important to
address is the general-purpose workcenter, a group of machines and personnel that produce a variety of part numbers and lot sizes. “These are like job shops, they produce no predetermined volume and they are much more concerned about cycle time and idle time,” said Hechtman. They want to collect data about their downtime reasons, he said, which usually goes along with OEE, but in these cases the classic formulation of OEE provides limited insight. “It only tells you how you did during production on that equipment. It does not refl ect times when you were not doing production,” Hechtman explained. “For example, in a bottling plant, if you ran it for one shift, it does not tell you how well you are using that asset. It only tells you how well you did while running that one shift.” That is why he also advocates using Total Effective Equipment Performance, or TEEP, implying that this calculation will be in the next release of the OEE module for Ignition. TEEP measures OEE against calendar hours, for example 24 hours per day, 365 days per year. It gives the bottom line assessment of utilization of assets. (A number of other people interviewed for this article also pointed to the value of TEEP.) Hechtman’s discussion about workcenters and variety also points to an ongoing issue with OEE, the variety of ways it can be calculated. This might not be a good thing. “There
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