TPM Stop Reason Configuration

Equipment stops in a production can occur for a multitude of different reasons. Unintended stops ('not scheduled') are to be taken into account for the OEE calculation, while scheduled stops are not meant to affect it.

Different reasons for equipment stops and how they affect the calculation of OEE, are configured in TPM Stop Reason Configuration objects.

Equipment stops are recorded in the 'Equipment Stops' table by the OEE Equipment Monitor which tracks error code or failure inputs. Equipment stops recorded in this way will initially be assigned a “0 - No Reason” code, until an operator overrides this data in the table with the actual stop reason. The Stop Reason Configuration object can be used to automate this step, provided that the machine being monitored emits sufficiently detailed error codes that can be directly associated with the defined Stop Reasons. How this is done, will be covered in the section on Mapping Error Codes to Stop Reasons.
Which Stop Reasons indicate scheduled and which indicate not-scheduled stops, depends on the configuration of their Stop Classifications.
These configuration options can either be applied to Built-in Stop Reasons or User-defined Stop Reasons.

This configuration object type can be created on Site, Area and Cell level.

A fully configured Site Configuration object is required for this configuration object to work properly.

Creating a TPM Stop Reason Configuration Object

  1. To create a TPM Stop Reason Configuration object, in the ISA-95 Equipment Model right-click on the intended parent object of one of the types listed above and select Admin  New  TPM  Stop Reason Configuration to open the Create Stop Reason Configuration wizard. In this example we will configure the Stop Reasons for a whole Site, therefore we will use 'The OEE Demo Site' .

  2. Enter a suitable name, and optionally a description for the object. Then click Next to continue.

    Stop Reason Configuration
    Figure 1. Stop Reason Configuration
  3. Click Create to create the Stop Reason Configuration object in the ISA-95 Model.

    The New Stop Reason Configuration Object in the ISA-95 Model
    Figure 2. The New Stop Reason Configuration Object in the ISA-95 Model

Linking the TPM Stop Reason Configuration Object to the OEE Equipment Monitor

To specify the TPM Stop Reason Configuration for the OEE Equipment Monitor, follow these steps:

  1. Go to the Configuration Options section in the monitor’s properties and click on …​ button for the Stop Reason Configuration Source to open the object picker in the ISA-95 Model.

    Setting the Stop Reason Configuration Source
    Figure 3. Setting the Stop Reason Configuration Source
  2. Select the intended Stop Reason Configuration Object from the ISA-95 Model.

    Linking the TPM Stop Reason Configuration to the OEE Equipment Monitor
    Figure 4. Linking the TPM Stop Reason Configuration to the OEE Equipment Monitor
  3. Click OK to confirm and close the dialog. Finally, Apply the changes to the properties.

Built-in Stop Reasons or User-defined Stop Reasons

The system offers a wide range of Built-in Stop Reasons which can also be further customized alternatively User-defined Stop Reasons can be used. Mixing Built-in Stop Reasons and User-defined Stop Reasons is not possible.
The Stop Reason Codings Source property defines which kind of Stop Reasons will be applied by the OEE Equipment Monitors using this Stop Reason Configuration object.

The decision, which of the two Stop Reasons options is to be used, must be made before the OEE Equipment Monitor is launched for the first time. Switching the configuration of the Stop Reason Codings Source property from one option to the other, once the OEE Equipment Monitor has been started, will ruin the OEE calculation.

Built-in Stop Reason Configuration

Built-in Stop Reasons as well as Custom Stop Reasons derived from them are configured in the Common section and can be translated for the use in WebStudio in the Translations section.

By default, all Built-in Stop Reasons are regarded as 'not scheduled', but this behavior can be overridden using this configuration object as described in the section on Overriding the Classification for Built-in Stop Reasons.
The Properties for the Built-in Stop Reasons
Figure 5. The Properties for the Built-in Stop Reasons

Creating Userdefined Stop Reasons

User-defined Stop Reasons allow the definition of proprietary Stop Reasons which are completely independent of those which are built-in in the system. They, together with their translations for WebStudio, are configured in the Userdefined Stop Reason Configuration section.

To add Userdefined Stop Reasons, …​

  1. Click on the table icon for the Userdefined Stop Reasons property, and

  2. Click on the + icon to add a new row to the table.

  3. Enter a unique ID in the 'Stop Reason' column.

  4. In the 'Stop Reason Tag' column provide a telling name/ short description for this specific reason.

  5. From the drop-down list in the 'Stop Classification' column select how this reason affects the OEE calculation:

    Table 1. The Stop Classification Options and how they affect OEE
    Value Effect on OEE

    Failure

    affects all OEE calculations

    Scheduled Stop

    does not affect any OEE calculation

    Unplanned Stop

    does not affect the calculation of OEE Solitaire

    Planned Stop

    does not affect the calculation of OEE Solitaire

Instead of actually deleting entries from this table, the Is Deleted column should be used to make Stop Reasons no longer available in WebStudio. Actually deleting an entry from the list could adulterate OEE calculations for historical data.

Userdefined Stop Reason Configuration

Normally, User-defined Stop Reasons are configured when they are created (see the previous section).
Otherwise they are generally configured in the same way as Built-in Stop Reasons. Therefore the following sections apply to Built-in Stop Reasons as well as to Userdefined Stop Reasons. Differences are be specifically addressed.

Mapping Error Codes to Stop Reasons

For Stop Reasons to be automatically assigned a failure reason, the corresponding error code needs to be mapped in the OEE Equipment Monitor > Performance Options > Equipment Failure Options. This is covered in the OEE Equipment Monitor Setup page.

Setting the Stop Classification

The Stop Classification defines if and how a Stop Reason affects the calculation of OEE.

This needs to be configured for User-defined Stop Reasons while all Built-in Stop Reasons are by default classified as 'unscheduled' stops, i.e. these stops affect the calculated OEE indices. Assigning a 'Stop Classification' to a Built-in Stop Reason overrides the default behavior.

The following table describes how the various options affect the OEE calculation:

Table 2. The Stop Classification Options and how they affect OEE
Value Effect on OEE

Failure

affects all OEE calculations

Scheduled Stop

does not affect any OEE calculation

Unplanned Stop

does not affect the calculation of OEE Solitaire

Planned Stop

does not affect the calculation of OEE Solitaire

To set the Stop Classification …​

  1. Select the Stop Reason Configuration object and go to the Properties Panel. Expand the Common section and click on the table icon for the Stop Reasons property for Built-in Stop Reasons; For User Defined Stop Reasons expand the Userdefined Stop Reason Configuration property compound and click on the table icon Userdefined Stop Reasons

  2. Click on the + icon to add a new row to the table.

  3. From the drop-down list in the 'Stop Reason' column, select the reason for which you want to overwrite the default behavior.

  4. In the Stop Classification column, select the appropriate option (see the table below).

    Overriding Built-in Stop Reasons as 'Scheduled'
    Figure 6. Overriding Built-in Stop Reasons as 'Scheduled'
  5. Then click OK to confirm and apply your changes.

Creating Custom Stop Reasons

Custom Stop Reasons can be created, following these steps:

  1. Select the Stop Reason Configuration object and go to the Properties Panel. Expand the Common section and click on the table icon for the Custom Stop Reason Configuration property.

  2. Click on the + icon to add a new row to the table.

  3. In the 'Parent Stop Reason' column, select the Stop Reason (category) underneath which the new Custom Stop Reason should be placed. For this example, select '021010 - Lunch Break'

  4. In the 'Custom Stop Reason ID' enter a unique ID. For organizational reasons it might be helpful to base this ID on the Parent Stop Reason’s ID. For this example, enter '021010-01'.

  5. In the 'Custom Stop Reason' column, give the reason a name, using 'Coffee Break' for this example.

  6. In the 'Stop Classification' column the way how this Custom Stop Reason affects oee, can be specified as described in the previous section on Setting the Stop Classification

    The Custom Stop Reasons Table
    Figure 7. The Custom Stop Reasons Table
  7. (optional) For filtering which Stop Reasons are to be displayed in WebStudio, using the Stop Reason Filter Options in OEE Equipment Monitor objects, custom attributes can be set in columns 'Custom Attribute 1 .. 3'.
    How these attributes can be applied for filtering is described in the OEE Equipment Monitor Setup.

  8. When you are done, click OK to confirm and apply your changes.

Deleting Stop Reasons

Deleting a Custom Stop Reason or a User-defined(Custom) Stop Reason might affect the OEE Calculation for historical Data! So don’t delete rows from these tables unless you are sure that this Reason was never applied to OEE calculation. Instead, for Stop Reasons which you want to remove, select the checkbox in the 'Is Deleted' column. Stop Reasons which have this checkbox selected, will no longer be applied or displayed in any other place but remain available for later reference.

Translating Stop Reasons

Translations for how Stop Reasons are displayed in WebStudio can be configured for ranges of Built-in Stop Reasons and for and individual Built-in Stop Reasons as well as for Custom Stop Reasons. Translations can be configured for multiple languages. They will be applied according to the browser language preferences. The default language of the system will be used as a fallback if there is no match between browser preferences and configured Stop Reason Translation language.

Stop Reason Range Translation

Translations based on Reason Range Codes are configured following these steps:

  1. Select the Stop Reason Configuration object and go to the Properties Panel.

  2. Expand the Translations section and click on the table icon for the Reason Range Codes Translation property.

  3. To add a new language, click on the 'New Column' icon.

    Adding a new column
    Figure 8. Adding a new column
  4. In the Column Settings dialog, for Column Name enter the ISO-639-1 language code (e.g. 'DE' for German) and click OK to create the new column.

    Setting the target language as column name
    Figure 9. Setting the target language as column name
  5. Click OK icon to close the Column Settings dialog and add the new language column to the table.

  6. Click the + icon to add a new row to the table.

  7. From the drop-down list in the 'Reason Range ID' column select the range ID which should be translated and enter the translation string in the language column(s).

    For Userdefined Reason Range Codes Translations this can not be selected from a drop-down list but the ID as specified in the Userfdefined Stop Reason Range table needs to be entered.
    Selecting the range and providing the translation
    Figure 10. Selecting the range and providing the translation
  8. When the translations for all the Reason Range IDs have been provided, click OK to close the Table Property Grid.

  9. Finally Apply the changes to the Object Properties.

Individual Stop Reason Translation

To provide translations for individual Built-in Stop Reasons, follow these steps:

  1. Select the Stop Reason Configuration object and go to the Properties Panel.

  2. Expand the Translations section and click on the table icon for the Reason Codes Translation property.

  3. To add a new language, click on the 'New Column' icon.

  4. In the Column Settings dialog, for Column Name enter the ISO-639-1 language code (e.g. 'DE' for German) and click OK to create the new column.

  5. Click OK icon to close the Column Settings dialog and add the new language column to the table.

  6. Click the + icon to add a new row to the table.

  7. From the drop-down list in the 'Reason ID' column select the Reason ID which should be translated and enter the translation string in the language column(s).

    For Userdefined Reason Codes Translations this can not be selected from a drop-down list but the ID as specified in the Userfdefined Stop Reason table needs to be entered.
    Selecting the Reason ID and providing the translation
    Figure 11. Selecting the Reason ID and providing the translation
  8. When the translations for all the Reason IDs have been provided, click OK to close the Table Property Grid.

  9. Finally Apply the changes to the Object Properties.

Custom Stop Reason Translation

To translate Custom Stop Reasons …​

  1. Select the Stop Reason Configuration object and go to the Properties Panel.

  2. Expand the Translations section and click on the table icon for the Custom Reasons Translation property.

  3. To add a new language, click on the 'New Column' icon.

  4. In the Column Settings dialog, for Column Name enter the ISO-639-1 language code (e.g. 'DE' for German) and click OK to create the new column.

  5. Click OK icon to close the Column Settings dialog and add the new language column to the table.

  6. Click the + icon to add a new row to the table.

  7. In the 'Custom Reason ID' enter the ID of the Custom Stop Reason for which translations should be provided.

  8. In the 'Translation Target' column select which property of the Custom Stop Reason this translation refers to.

    Selecting the Translation Target
    Figure 12. Selecting the Translation Target
    If multiple properties of a Custom Stop Reason are to be translated, each property requires an individual row in this table (with the same value in Custom Reason ID column).
  9. Enter the translation for the target property in the language column(s)

    The complete row for a Custom Reasons Translation
    Figure 13. The complete row for a Custom Reasons Translation
  10. When you’re done, click OK to close the Table Property Grid.

  11. Finally Apply the changes to the Object Properties.