Machine status monitoring
Through the OEE Cockpit, every system user has access to the current machine status. Thanks to such machine monitoring functionality, the reaction time to harmful events can be reduced to a minimum. The machine status module collects data in real time, converts it and presents it in an easy-to-understand graphic form. The collected data on the machine status are not only presented on-line, but saved and available through a series of historical reports in machine monitoring module follow-ups.
At Operator Systems, we know that mobile plant monitoring capabilities are becoming increasingly important to our clients. That’s why we created Operator OEE Mobile – a dedicated suite of applications for mobile devices that e.g., displays your current machine statuses from the Operator MES, in an easy-to-read format, or it makes registration of Stop and Scrap mobile codes. In the Mobile Operator OEE APP, the status of each machine is listed, and the statuses are labeled and color-coded. The application also includes a column displaying the duration of each status.
The target form OEE is to keep the highest possible availability and performance. Therefor we have developed a Maintenance Alert & Tracking APP suite. This APP suite make it possible to alert the Maintenance department as soon as a machine has a critical stop or damage. The functionality is simple, the shop floor operator pushes a button and at the same time the Maintenance employees receive the alert on their Mobile Operator APP with exact information received from the OEE. They can then start a Maintenance workflow and the Operator solution make sure that all activities and events are traced and tracked.
At a glance, you can have the “on-line” status of the machines or the line/machine positions that are handled at the terminal. The Operator OEE screen shows the machine status and performance on the shift/day level.
This functionality allows you to monitor real-time machine status (which machines are stopped, or operating at reduced or normal speed). It is a robust tool for identifying the exact amount of production losses and their reasons, as well as for calculating and showing the status of the most important KPIs (like OEE), in real-time.
It also allows you to view production operations and schedule execution progress. So on one screen you have detailed information about the production process execution. OEE can also be used to measure and document the improvements achieved by Lean initiatives.
Operator OEE software is easy to install, use and maintain, and delivery of immediate OEE gains of 5%–10% are commonly achieved. Operator Systems has proven successful implementations with a ROI in about 6–12 months.
Contact us and we will help you calculate the potential Return Of the Investment in the Operator OEE system or use the ROI calculator, which can be found in the upper right corner of our website.
Machine monitoring is a multi-level activity with multidimensional benefits. The aim of these activities is to implement changes that increase the efficiency of manufacturing companies, including improving the quality of manufacturing products, optimizing equipment operation and reducing energy consumption. To make it possible, it is necessary to precisely determine the technical condition of machines: continuously observe machine status, their efficiency and to check the quality of materials and manufactured products. Then it is necessary to process the data affecting the obtained results and to introduce necessary changes and improvements of the processes. The OEE Operator system allows the connection to the machine controllers (PLCs) via the OPC standard. Therefore, thanks to the PLC it is possible to monitor and even control the machine and its operation from the level of the supervisory system (MES/OEE).
Monitoring of machine efficiency during operation
Monitoring of machines in the production plant by means of mobile devices enables many benefits for the customers. With our suite of functionalities, it is possible to monitor machine status and track the performance of production assets in real time. This allows you to know the status of your company’s machines anytime, anywhere without having to check or involve a third party. It is a significant simplification that allows to achieve higher productivity and efficiency of production processes. The main objective of the Operator OEE system (including Mobile OEE APP) is to increase the optimization and efficiency of machinery operation.
Monitoring of machines with Mobile OEE APP
The purpose of our Mobile OEE APP is to properly support production management in monitoring resources in order to increase productivity. By using PLC and OPC technology, it is possible to achieve the highest efficiency during operation. The moment a machine breaks down or stops working, a notification is sent. Which contains the relevant data, allowing you to get an answer about the causes related to the technical status. You will know the status of the machines by their color and description. In addition, you will also find the duration of each machine and information about the current production in progress as well as who is operating the machine.
OPC and PLC integration as effective support for business efficiency
A necessary element for acquiring meaningful data is the creation of appropriate optimization procedures. The most commonly used solution for standard data exchange in industrial enterprises is the OPC system. The aim is to improve configuration and integration and to complete tasks in significantly less time while reducing costs. This is why OPC UA has so many supporters among businesses.
OEE (Overall Equipment Effectiveness) is a composite indicator designed to measure the performance of production assets and provide information about the entire production process, such as the performance of an assembly line. The term “effective productivity” is used to indicate that machines are being used more efficiently.
OEE is a composite indicator that reflects the efficiency of a plant. OEE consists of four components: availability, efficiency, quality, and productivity. These components can be measured by three indicators: availability rate (AR), performance rate (PR), and quality rate (QR).
OEE can be represented as follows:
OEE = AR × PR × QR
OEE measures how efficiently machines, equipment, and labor are used to produce the product. When it comes to OEE, efficiency is one of the most important metrics. If you can increase your efficiency in any way, then it will have a big impact on your company’s bottom line.
Effective equipment is more profitable for manufacturers because they are paying less for maintenance costs and have increased production rates. Plus, they are requiring less of their workforce which means they have more time available for other tasks that will increase profits even further.
The use of machine monitoring allows to increase the efficiency of the production process, including minimizing downtime. All thanks to real-time machine status tracking.
Production lines have always been plagued by problems that interrupt flow and affect productivity, but now, with machine monitoring solutions, these problems can be detected and stopped before they turn into a larger-scale problem.
Machine monitoring allows you to monitor the status of all equipment connected to your system and is especially useful for those that are prone to failure, such as motors or valves.
Machine status monitoring tools are used in the manufacturing industry to improve production efficiency. Some of these tools include PLC and OEE.
PLC (Programmable Logic Controller) is a computerized system that controls the industrial process through data entry and gives feedback on the status of machines, among other things, minimizing downtime. OEE (Overall Equipment Effectiveness) is a yardstick that measures how well manufacturing equipment performs over a specified period of time. It analyzes the quality, performance and availability of production resources.