The OEE Equipment Monitor Setup

With the OEE Simulation prepared and a Timezone and Availability Tracker configured for the Connector where the simulation data is produced, the time has come to create the OEE Equipment Monitor as the central element of OEE calculation in system:inmation.

Go to the ISA-95 Equipment Model and select the asset, for which you want the OEE indices to be calculated. In our example this is 'The OEE Demo Cell'. Right click on this object and select Admin  New  TPM  Equipment Monitor to open the Create Equipment Monitor wizard which we will now go through step by step.

Creating a new OEE Equipment Monitor object
Figure 1. Creating a new OEE Equipment Monitor object

The Common Section

In the Common section, give the new object a suitable name and, optionally, add a description of the object’s function. Leave the Processing Mode on 'Configuration'. When done, click Next to go to the next section.

The Common Section
Figure 2. The Common Section
For initial setup and all later configuration changes, the Processing Mode should be set to 'Configuration'. Setting this to 'Production' to starts the OEE calculation.

Configuration Options

The Configuration Options can link to specific OEE Configuration Objects, which will be addressed later, when we are Adding Configuration Objects. For this basic example no Configuration Objects are needed, so you can skip this section by clicking Next once more.

Processing Options

For information regarding the individual properties refer to the Processing Options section in the TPM OEE Equipment Monitor class.

In the Processing Options select a Trigger Source which indicates the start and end of a production cycle and trigger the OEE calculation. In this example, please select 'Quantity Dropped', then click Next.

Trigger Condition: Quantity Dropped
Figure 3. Trigger Condition: Quantity Dropped

Measurement Options

For information regarding the individual properties see the Measurement Options section in the TPM OEE Equipment Monitor class.

The Measurement Options inform the OEE Equipment Monitor about how the product is measured. The Performance Measurment Type specifies if Discrete Units are to be counted or Volume or Mass to be measured. Depending on the selection here, individual options allow to specify the unit in which the product which is produced on this asset is measured. For the example, leave everything in it’s default setting and click Next to continue.

Measurement Options
Figure 4. Measurement Options

Availability Options

For information regarding the individual properties see the Availability Options section in the TPM OEE Equipment Monitor class.

The Availability Options inform the OEE Equipment Monitor about the planned availability of the asset. Default value is 'Continuous Availability (24/7)' but it can also be set to 'Shift Regime', which means there is a more detailed availability configuration, defined in a specific TPM Shift Configuration Object. This object will be addressed later.

For this example, leave the Availability Type on its default value 'Continuous Availability (24/7)' and click Next to continue.

Availability Options
Figure 5. Availability Options

Quantity Options

For information regarding the individual properties see the Quantity Options section in the TPM OEE Equipment Monitor class.

The Quantity Options link the OEE Equipment Monitor to the objects in the I/O Model which hold the current quantity data for the production. In other words, these fields tell the monitor how much was produced and possibly rejected.

Quantity Options
Figure 6. Quantity Options

Add the Total Quantity Input. To do this click the …​ icon for this property, expand the I/O Model tree and select the 'QuantityTotal' variable object from the OEE Simulator, then click OK to confirm your selection and close this dialog window.

Selecting the Good Quantity Input
Figure 7. Selecting the Total Quantity Input

Then add the Good Quantity information: Check the checkbox for Good Quantity Available and select the Good Quantity Input in the same way as the Total Quantity Input. Then click Next to continue.

The Quantity Configuration with Quantity Inputs selected
Figure 8. The Quantity Configuration with the Quantity Inputs selected

Performance Options

For information regarding the individual properties see the Performance Options section in the TPM OEE Equipment Monitor class.

In the Performance Options section the key values regarding the asset’s performance are configured. The 'Default …​' values are asset specific.

Product Options

The Performance Options Page
Figure 9. The Performance Options Page

In the Product Options section the ideal production outputs are defined. Product specific values can be entered in a table and default valued provided, if the product can not be found in this table.

Products are identified by their name, which has to be provided by an object in the I/O Model tree. To connect the OEE Equipment Monitor to this object, it again has to be selected as the Product Name Input, clicking on the …​ icon.

Selecting the Product Name Input
Figure 10. Selecting the Product Name Input

Then click on the 'table' icon for the Product Configuration property to open the Product Configuration table. For each product defined in the OEE Simulator script add a line, entering the values for 'Product Name' and 'Performance' from the 'Product Database' section of the script.

The Product Configuration Table
Figure 11. The Product Configuration Table

Click OK to close the table.

All Performance Optins Sections
Figure 12. All Performance Options Sections

If configured, Default Performance, Default Quantity Multiplier, and Default OEE Target will be used as fallback values if the current product can’t be found in the Product Configuration Table.

Equipment State Options

To be able to consider the state of an equipment in the OEE calculation, the OEE Equipment Monitor needs to be linked to an object in the I/O Model which can be used as the Input for the current state of this equipment. This state has to codified according to the EquipmentStates Coding Group

Set the Equipment State Input to be linking to the 'Equipment State' object of the OEE Simulator, in the same way as the other Inputs before.

The system uses Equipment States according to the ISA-88 specification. To be useful for the OEE Monitor, these status codes need to be translated into the corresponding TPM Time Categories. This translation is configured in the State Time Assignment table.

Click on the table icon for State Time Assignment property.

Opening the State Time Assignment table
Figure 13. Opening the State Time Assignment table

In the table, add a line for each state which is to be mapped. In each line select the Equipment State and the corresponding Time Category from the respective drop-down lists.

Selecting the Equipment State
Figure 14. Selecting the Equipment State

For our example, set the State Time Assignment table to match the following configuration:

The State Time Assignment table for the example
Figure 15. The State Time Assignment table for the example

Then click OK to close the table display.

Equipment Failure Options

Failures can be signalled to the OEE Equipment Monitor object in four different ways: by an error flag, an error code, an error message or an OPC A&E message.

Since the OEE Simulator script sends out error codes in case of failure, we select its Error Code variable in the I/O Model as the Equipment Error Code Input property.

Selecting the Error Code Input
Figure 16. Selecting the Error Code Input

When all Performance Options are configured, click Next to continue.

Context Options

For information regarding the individual properties see the Context Options section in the TPM OEE Equipment Monitor class.

Our example is running a batch production, so we provide a link to the BatchID Input by clicking on the …​ icon …​

Select the Batch ID Input
Figure 17. Select the Batch ID Input

... selecting 'Batch ID' from the OEE Simulator in the I/O Model tree and clicking OK to confirm the selection and close the object picker window.

Select the Batch ID Input from the I/O Model tree
Figure 18. Select the Batch ID Input from the I/O Model tree

Stop Reason Filter Options

The Stop Reasons Filter Options are used to restrict the options which will be available in WebStudio when annotating stop records with stop-reason codes.

The system has a number of built-in reasons for equipment stops, which may be assigned to stops in the OEE Equipment Stops table. By default all stops affect the calculation of the OEE Indices. This behavior can be overridden in Stop Reason Configruation Objects. Also Custom Stop Reasons can be defined there.
NOTE: Micro stops don’t affect the Availability Index, but rather the performance metric.

In the Stop Reason Filter table ranges of Stop Reasons which will be made available in WebStudio can be specified.

If no range is specified in this table, all defined Stop Reasons will be available in WebStudio. If at least one range is defined in this table, only the Stop Reasons which are included in the specified range(s) will be visible.

To add a range of Stop Reasons, follow these steps:

  1. In the Stop Reason Filter Options, click on the table icon for the Stop Reason Filter property to open the Table Property Grid.

  2. In the Table Property Grid, click on the + icon to add a new line to the Stop Reason Filter table.

  3. In this new line, select the first Stop Reason of such the range from the drop-down list in the Stop Reason From column.

  4. Select the last Stop Reason of this range from the drop-down list in the Stop Reason To column.

    Filtering Built-in Stop Reasons
    Figure 19. Filtering Built-in Stop Reasons

  5. Click OK to close the Table Property Grid.

  6. Finally, Apply the changes to the properties.

Filtering Custom Stop Reasons

The Custom Stop Reason Filter property is used to define filters on the attribute fields of custom stops reasons. When editing the stops reasons in WebStudio, all available reason codes and custom stop reasons are presented to operators for selection.

It may however be that some stop-reasons only apply to certain machines, which is indicated by setting one or more of their attributes to the machine type or model or make for example.

The set of custom stop reasons presented to users in WebStudio can be controlled by defining filter expressions. Each row in the configuration table is set to contain strings that should match with corresponding attributes. A reason is included if any of the row expressions match. For example, suppose we want to return all custom reason strings where (attribute1 == “X” and attribute2 == “Y”) or (attribute1 == “Z”). This would be accomplished with the following settings in the filter table:

Table 1. Custom Stop Reason Filter Example
Custom Filter 1 Custom Filter 2 Custom Filter 3

X

Y

Z

The 'Custom Filter' columns correspond to the Custom Attribute columns of TPM Stop Reason Configuration objects. If the defined Custom Attributes match the corresponding Custom Filters, the Stop Reason will be visible.

Filtering Custom Stop Reasons
Figure 20. Filtering Custom Stop Reasons
Custom Stop Reasons Filters are additive to the Stop Reason Filters. This means that Custom Stop Reasons will be included in the list of visible Stop Reasons if they are included in the Custom Stop Reason Filter - even if they fall within a range which is NOT included in the Stop Reason Filter.

Finishing this Setup

Now all of the relevant configurations for the OEE Demo Equipment Monitor have been made, so click Create to create the monitor object.

Batch ID Input selected for the Context Options
Figure 21. Batch ID Input selected for the Context Options

The new OEE Equipment Monitor object will appear underneath the cell for which we created it.

The new OEE Equipment Monitor in the ISA-95 Model
Figure 22. The new OEE Equipment Monitor in the ISA-95 Model