Datonis Manufacturing Intelligence Beta

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Revision as of 10:41, 15 April 2020 by Pushkaraj (talk | contribs) (Updated production timeline section)
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Contents

  1. Getting Started
    1. About Datonis Manufacturing Intelligence (MInt)
    2. Different Aspects of MInt
  2. MInt Configuration
    1. General Configuration
      1. Define Hierarchy (Department-Cell/Line)
      2. Define Workcenters (i.e. Machines)
      3. Define Shifts & Shift Plan
      4. Define Preplant Downtime (Add Holidays)
    2. Productivity Configuration
      1. Define Part and Part Quality Parameters
      2. Add Operators
      3. Add Tools
      4. Production Notification
      5. Define Downtime Reasons
      6. Configure Production Alerts
    3. CBM Configuration
      1. TPM Classification
      2. Parameter Criticality
      3. Define CBM Notification
      4. Add CBM Alerts
    4. Quality Configuration
      1. Configure Rejection Codes
      2. Configure Inspection Policies
  3. MInt Reports & Dashboards
    1. Productivity Module
      1. Productivity Module
        1. Management Dashboard
        2. Productivity at Cell / Line
        3. Productivity at Workcenter
      2. Productivity Analysis for Cell / Line
      3. Productivity Analysis for Workcenter
      4. Timeline (Gantt Chart) View
    2. CBM Module
      1. Definition
      2. CBM Dashboard for Cell / Line
      3. Workcenter CBM Dashboard
        1. Parameter SPC Report
      4. Workcenter Maintenance
    3. Quality Module (Part Quality)
      1. Definition
      2. Part Quality Dashboard
        1. Quality Parameter Analysis
        2. Quality Parameter SPC Report
    4. Energy Module
      1. Definition
      2. Energy Dashboard at Cell / Line
      3. Energy Dashboard at Workcenter
      4. Energy Analysis at Cell / Line
      5. Energy Analysis at Workcenter
    5. Workorder Module
      1. Definition
      2. Workorder Dashboard
      3. Workorder Details

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 level 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. This means that there is a sequential work that happens when producing a part.

When user selects the cell from the Cells, 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 ‘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 is the report capturing the productivity elements at the workcenter. This is same as the report covered under 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:

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