Difference between revisions of "Datonis Manufacturing Intelligence Beta"

Revision as of 12:51, 16 April 2020

Getting Started

About Datonis Manufacturing Intelligence (MInt)

Datonis Manufacturing Intelligence (MInt) is a cloud-based software which transforms the organizations (Plant) manufacturing related data from heterogeneous sources to depict a comprehensive 360-degree view of the plant. Today’s BI tools are very mature in data presentation and flexible in adaptation, but this doesn’t help those working on the shop floors that need to contextualize their analysis of data with the actions they are performing. Propagation of the information between systems and people (including shop floor operators) is the real need of the manufacturing industry.

Different Aspects of MInt

The following are Datonis Manufacturing Intelligence (MInt) key characteristics:

• Datonis Manufacturing Intelligence completely depicts the end-to-end manufacturing process
• A single portal which transforms and displays data with various angles like Productivity, Quality, Energy and Work order
• Preventive Maintenence with condition-based monitoring (CBM).
• Act with real-time insight: Passing data between enterprise-level and plant floor systems to display reports, analysis, visual summaries so that from a floor manager to the plant management can take informed decisions.
• On-Demand Monitoring: Datonis Manufacturing Intelligence has a fluid design and adapts to the target device screen, so you can monitor machines and access reports literally on the go.

MInt Reports & Dashboards

Productivity Module

Most of the times Productivity and Efficiency in manufacturing world get misinterpreted or sometimes used synonymously. But Production is a measure of output only and it is different from efficiency of the organization.

Productivity is the important aspect of Datonis Manufacturing Intelligence. It is one of the basic variables governing economic production activities. However, at the same time as productivity is seen as one of the most vital factors affecting a manufacturing company’s competitiveness.

Overall Equipment Effectiveness (OEE) is a benchmark and a baseline for measuring manufacturing productivity. OEE is calculated based on Availability, Performance, and Quality. Each factor represents a different perspective for how close the current manufacturing process is to Ideal Production. Datonis Manufacturing Intelligence covers the Productivity at the Department, Cell/Line and at Workcenter (Machine) level.

Datonis Manufacturing Intelligence portraits productivity in the following manner:

Management Dashboard

This workspace captures the productivity elements at all the Organization level. The dashboard shows summarized insights for the key KPIs like OEE, Production Quantity, CBM Alerts and Quality Alerts. This dashboard gives a bird’s eye view to the key plant stakeholders as well as executive management.

This has the following sections:

• Cells: This shows the combined KPIs OEE, Production Quantity, CBM Alerts and Quality Alerts.
• Lines: This shows the Line-level OEE, Production Quantity, CBM Alerts and Quality Alerts KPI.

(Alerts are covered in detail in the CBM and Quality modules)

Productivity Dashboard

This is a live dashboard which shows key productivity KPIs like OEE, Production Quantity, Stoppages, Hourly Production and Top Losses for selected Cell or Line. The data shown is live data for the ongoing shift. The user can view historical data using date and shift filter.

Productivity at the Cell level

A Cell is a logical un-ordered set of workcenters whereas Line is an ordered set of workcenters. When user selects the cell from the Cells/Line filter, this shows the consolidated data for all workcenters defined under the selected cell. The dashboard displays OEE, Availability, Performance, Quality at a glance.

The following are the formulae used to calculate the Key KPIs:

• Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
• Availability = Operating Time / Scheduled Time
• Performance = (No. of parts * Ideal cycle time ) / Operating Time
• Quality = (No. of good parts / Total parts produced ) * 100

The dashboards also display also following set of KPIs: Capacity Utilization, Uptime, Planned Downtime and Unplanned Downtime.

The following are the formulae used to calculate the KPIs:

• Effective Working Time (EWT) = Total available time - Planned maintenance
• Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT

Productivity at the Line level

A production line is a series of process steps, where the form fit or function is changed at each step to produce a product.

When the user selects the cell from the Lines, this shows the data for the last operation defined under the selected Line. The dashboard displays OEE, Availability, Performance, Quality at a glance.

The following are the formulae used to calculate the Key KPIs:

• Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
• Availability = Operating Time / Scheduled Time
• Performance = (Actual Production/Line Speed) / Operating Time
• Quality = (No. of good parts / Total parts produced ) * 100

The dashboards also display also following set of KPIs: Capacity Utilization, Uptime, Planned Downtime and Unplanned Downtime.

The following are the formulae used to calculate the KPIs:

• Effective Working Time (EWT) = Total available time - Planned maintenance
• Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT

In the dashboard, the next section explains about the Production Quality and Production Losses.

Production Quality

The dashboard displayed the ‘Total Production’ and shift wise bifurcation along with the number of cycles it took to produce the production quantity. The dashboard also plots a bar graph to display hourly production and cycles.

• Cycle Time = Loading Time + Machine Auto Cycle + Unloading Timeline

(Quality aspect is discussed in detail in the Quality Module)

Production Losses

This section of the dashboard displays the production losses i.e. unplanned downtime. Again, the cumulative losses (downtime) is displayed. This also shows ‘Major’ and ‘Minor’ stoppages, the user can set the threshold for minor stoppages.

The user can also view ‘Loss Analysis’ detailed report by clicking on the icon which leads to the report. Loss Analysis at Cell/Line and workcenter level

Productivity at Workcenter

This mainly depicts Total Production, Cycles, OEE, availability, performance, Quality for each workcenter in the cell in a tabular format. This also shows the Total Production, Capacity Utilization (CU), Up Time and Down Time. This also shows Uptime, Planned and Unplanned Downtime, Capacity Utilization and name of the operator operating the workcenter.

By clicking a hyperlink (on the name of the workcenter) user can open a ‘Workcenter Productivity Dashboard’ where the user can see the same KPIs for the selected workcenter.

Demo Video: https://drive.google.com/file/d/13aebJxH9Q5u72VrUW6romwsLFwMR_tDZ/view?usp=sharing

Productivity Analysis for Cell / Line

The Productivity Analysis report plots the key KPIs in the form of a trend. For the Cell/Line selected this shows all the indicators covering the performance measures of the Cell or line. A provision to download the data in CSV format for further statistical analysis has been given.

It shows a trend for OEE, Availability, Performance and Quality. Next to the trend chart, it also displays the KPIs in bar graph split by shift. This also covers the other productivity-related elements like Total Production, Total Down Time, and Capacity Utilization. The workcenters section shows workcenter level breakdown of above KPIs in table-format view. The user can sort on the KPI columns to represent the data in a desirable format.

A further drill-down report ‘Workcenter Trend Report’ is also available on click on the workcenter name, which is explained in the next section.

Demo Video:

Productivity Analysis for Workcenter

Workcenter Analysis captures productivity elements at the workcenter. This is same as the report covered in the above section. The report displays a trend for the period of the last 30 days for the selected workcenter. The report illustrates Key KPIs like OEE, Availability, Performance and Quality trend along with the shift level split. This too covers the other productivity-related elements like Total Production, Total Down Time, and Capacity Utilization for the selected workcenter.

Demo Video:

Production Timeline View

This dashboard shows the production timeline (Gantt Chart) since the beginning of the current shift. By default, displays the current day and current shift. The data for historical dates can also be rendered. The report shows the current running status of the workcenter with statistics like produced quantity, uptime and downtime. Production Quantity is parts produced in the shift. Uptime is a total time of all productive slots (Green Slots) in the shift, Downtime comprises of planned as well as unplanned downtime.

Key Slots: Productive Slots (Green Slots), Unplanned Downtime Slots (Red Slots) and Planned Downtime Slots (Yellow Slots)

A hyperlink is provided for each workcenter to drill down into a workcenter specific productivity dashboard.

Demo Video:

Loss Analysis

This report is currently under enhancement.

Workcenter Loss Analysis

This report is currently under enhancement.

Condition Based Monitoring Module

Condition Based Monitoring (CBM) plays a crucial role in preventive maintenance. Condition Based Monitoring is the process of monitoring a parameter of condition in work center (vibration, temperature etc.), in order to identify a significant change which is indicative of a developing fault. Condition Based Monitoring has a unique benefit in that conditions that would shorten normal lifespan can be addressed before they develop into a major failure. Datonis Manufacturing Intelligence has a separate workspace for Condition Based Monitoring (CBM).

Although there are few master data configuration related changes for CBM module. Those have been covered in the MInt Configuration Section.

CBM Dashboard

This is a Cell/Line level report which displays a holistic view of the defined Condition Based Monitoring (CBM) parameters for the select Cell/Line. The Report displays the data for a single day with the shift level drill-down option.

The report displays a consolidated number of points out of the limits for Critical Alerts and Warning Alerts, this also plots the machine wise bar graph for the for Critical Alerts and Warning Alerts for each workcenter. The user can click on the bar-graph to navigate to the Workcenter CBM Dashboard report.

The workspace also displays ‘Machine Overdue’ alert with a hyperlink for a drill-down view and cumulative major and minor stoppages for the selected Cell/Line for the selected day and shift.

The send half of the report displays the above KPI information i.e. Critical and Warning alerts, Major and Minor Stoppages and Maintenance overdue (Yes/No) in a tabular format. The user can click on the workcenter name to view the Workcenter CBM Dashboard report.

Workcenter Maintenance

The user can click on the ‘Maintenance Overdue’ tile to access this report. The repost displays the following information for the selected Cell/Line:

• Workcenter Name
• Health Remaining
• Last Maintenance Time
• Duration
• Likely Maintenance Due Time

The Report also provides two action buttons:

• Add Maintenance Record: The user can add a maintenance history for a workcenter. The form allows user to add Maintenance Start Time and End Time, Type (Planned or Unplanned), Maintenance Details and Maintenance Done By (which name of the person who has done the maintenance work.)

• Maintenance Record History: It displays the past records for the selected workcenter like Start Time, End Time, Duration (Hours), Threshold, Maintenance Details and Person who had done the maintenance.

Demo Video:

Workcenter CBM Dashboard

This report can be viewed by clicking on any workcenter from the CBM Dashboard. The report depicts a heatmap showing hourly summarized condition monitoring insights like critical and warning alerts, for the selected workcenter and parameters. The user can select multiple parameters. It also provides a raw data plot of the configured parameters with statistics like Min, Max, Avg, Std Dev, PoL, Dev from Target, Cp and CpK.

Detailed statistical tools (P, X, R, S, I-MR Chart) to analyse the variations in the parameters can be accessed by clicking on the CBM parameter name.

Parameter SPC Report

As described in the above report, the Parameter SPC report can be accessed by clicking on any workcenter parameter from the Workcenter CBM Dashboard. This report displays a run chart of the configured CBM parameters along with the SPC charts for the selected machine, Parameter, Date and Shift.

The first chart is a raw data run chart with user-defined control and warning limits. Along with the run chart some statistics of the data are shown alongside the chart. These include Min, Mean, Max, Std Dev, Dev from Target, Cp and CpK.

The next run charts are the SPC charts which include P chart, X chart, S chart, R chart, Individuals Chart and Moving Range chart.

Demo Video:

MTBF and MTTR Report

Mean time between failures (MTBF) is the predicted elapsed time between inherent failures of a mechanical or electronic system, during normal system operation.

• Mean Time Between Failure (MTBF): Total Down Time / Count of Down Time(s)

Mean time to recovery (MTTR) is the average time that a device will take to recover from any failure.

The first workspace displays overall MTBF/MTTR by reasons with an aggregated value for the selected Cell/Line for the selected period. A filter for the category is also available if the user wished to focus on a specific reason.

The subsequent report displays a line graph for each reason by plotting MTBF and MTTR values against the date on the x-axis.

Workcenter MTBF and MTTR Report

The reports display workcenter specific MTBF and MTTR. A filter for the category is also available if the user wished to focus on a specific reason.

The subsequent report displays a line graph for each reason by plotting MTBF and MTTR values against the date on the x-axis.

Demo Video:

Energy Module

Datonis Manufacturing Intelligence also covers the Energy workspace with two out of the box utilities i.e. electricity and Compressed Air. If a plant uses more utilities, there is a provision to add them. This gives an overview of the Utilities configured in the Plant.

Energy Dashboard

This is the Cell/Line level utilities consumption view. This dashboard shows summarized energy and utilities consumption metrics like Kilowatt Hour consumption (Kwh) for Electricity and the amount of compressed air for Compress Air. It displays the total consumption and hourly consumption since the beginning of the shift. This report also shows the workcenter summary which is nothing but the utilization of these metrics in each workcenter.

Workcenter Energy Dashboard

On the cell/line level Energy dashboard, the hyperlinks are provided to get detailed workcenter level insights into consumption patterns. This workcenter dashboard shows energy and utilities consumption metrics like total consumption and hourly consumption since the beginning of the shift.

Energy Analysis

This dashboard shows consumption trends for the selected cell/line over the selected period. The total consumption across different energy and utilities metrics are displayed. Shift level bifurcation is also provided for shift level consumption analysis. Workcenter level consumption data is displayed in a tabular format which can be sorted across different parameters. The workcenter consumption details can be accessed on hyperlinks.

Workcenter Energy Analysis

This report shows consumption trends for the chosen workcenter over the selected period. The total consumption across different energy and utilities metrics along with average consumption across shifts is also displayed.

Demo Video: