OEE Performance Software

Product Details:

Abstract:
This paper discusses performance management systems and the benefits of implementing such solutions using InduSoft Web Studio and InduSoft RealTime Performance Management. Examples of industries currently using performance management systems include Food and Beverage, Chemical, Pulp and Paper, Water and Waste Water, Pharmaceutical, BioTech, Oil & Gas, and Power Generation.

Business Drivers:
Performance management software systems are becoming an essential part of an overall business strategy for enterprises in the manufacturing and energy production industries. Businesses in these industries are employing it to drive their business toward optimal asset use and increased overall business performance. By collecting data from several different sources, such as plant-level and enterprise-level systems, information can be obtained, organized, analyzed and put into a format that leads to fact-based, data-driven decision making.

Regardless of the industry, most companies report that they realize benefits almost immediately and achieve a complete return on investment within six to twelve months. Even companies that historically spend a small percentage of their revenue on IT see performance management systems that analyze data in real time as an important component in helping to maximize their company’s productivity and profitability.

InduSoft RealTime Performance Management is an application template that, used in concert with InduSoft Web Studio, can assist companies in quickly and inexpensively developing and implementing performance management systems. Subsequent sections explain the components that compose such systems, how they work together, and the business value they provide.

Product Details:

Overall Equipment Effectiveness (OEE) is a method to measure three distinct Key Performance Indicators (KPI). The best SCADA software includes this functionality without requiring additional modules or add-ons to be purchased. In top SCADA software all the tools necessary for OEE management are built-in. Here are the three KPI:

Performance: Performance is the percentage of units created on a machine in relation to the expected output. If the specifications of the machine indicate that it can produce 1,000 units per hour, and produces 800, then the machine has an 80% performance KPI rating.

Availability: The percentage of the time the machine is online when it is scheduled to run is its availability. For a machine scheduled to run for ten hours, with three hours of downtime has an availability of 70%.

Quality: A machine's quality indicates the percentage of goods accepted in quality assurance. A machine producing 1,000 units an hour with 200 rejected has a quality KPI of 80% .

Why have an OEE application?
OEE is an important tool for a SCADA software user. By studying KPIs, plant managers can determine which machines or parts of the process are weak links. In a machine with performance is at 100%, but quality at only at 54% might trigger an alert telling a plant manager that they are off-target. Evaluating the OEE in SCADA software can help an operator visualize results. If performance is at 80%, and quality rises to 99%, it might be a good idea to slow production slightly for a better product. By reading the OEE dashboard when one machine operator is running the machine versus another operator, supervisors can determine which operators are producing more, and which need additional training.

The instructions to run this application are:

• Install IWSv7.1 SP3 (or later) in your computer

• Extract the files from OEEDemo_v713.zip into your computer

• Open IWSv7.1 SP3 (or later) development environment and run the OEEDemo application.

• Username: Guest

Product Details:

Accurate and timely production reports are key to the management decision making process.

• Automatic real-time Overall Equipment Effectiveness (OEE) calculations to identify cost reduction opportunities.
• Easy readability with a spreadsheet-like view of shift production activity.
• Complete production history reports—by date, shift, cell, work center or global—are always available.
• Variance reporting.

• Automatically calculated material usage, based on the BOM.

Product Details:

Machine Performance Monitoring

Machines and Systems for which Performance Monitoring surveys may be required on a routine basis include the following items:

• Pumps – due to impeller wear, seal ring wear (re-cycling) or blockage.
• Fan Systems – due to filter blockage, blade fouling or re-cycling.
• Boilers – due to loss of thermal efficiency for many different reasons.
• Heat Exchangers – due to fouling or blockage.
• Steam Turbines – due to blade fouling and numerous other reasons.
• Air Compressors – due to wear, filter blockage, valve leakage (reciprocating), etc.
• Diesel or Gas Engines – due to loss of compression (rings or valve leakage) etc.
• Electrostatic or bag dust filters – due to fouling, shorting or leakage.

Note that electric motors are not included on the list because fall-off in performance is usually measurable by standard condition monitoring processes such as vibration and thermography. Perhaps the most useful parameter for performance measurement of an induction motor is speed in relation to load. This should always be a constant and variations are measurable with vibration analysis. Therefore, generally speaking, special purpose performance monitoring surveys for electric motors are not required. Though the final decision to performance monitor motors should consider the risk associated with their failure.