Difference between revisions of "Datonis Manufacturing Intelligence Beta"

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==== About Datonis Manufacturing Intelligence (MInt) ====
 
==== About Datonis Manufacturing Intelligence (MInt) ====
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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.
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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.  
  
 
==== Different Aspects of MInt ====
 
==== Different Aspects of MInt ====
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* 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.
 
* 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.
  
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=== MInt Reports & Dashboards ===
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=== Basic Concepts ===
  
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==== Productivity Module ====
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==== Key Definitions ====
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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.
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KPI management first starts with understanding what to measure and then how to measure. The Datonis Manufacturing Intelligence has a well-defined measurement to monitor, analyze and optimize the defined production KPIs.
  
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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.
+
'''1) OEE''' - Overall equipment effectiveness (OEE) is a measure of how well a manufacturing operation is utilized (facilities, time and material) compared to its full potential, during the periods when it is scheduled to run.
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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.
 
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Datonis Manufacturing Intelligence portraits productivity in the following manner:
 
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===== Management Dashboard =====
 
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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.
 
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This has the following sections:
 
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* Cells: This shows the combined KPIs OEE, Production Quantity, CBM Alerts and Quality Alerts.
 
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* Lines: This shows the Line-level OEE, Production Quantity, CBM Alerts and Quality Alerts KPI.
 
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(Alerts are covered in detail in the CBM and Quality modules)
 
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===== Productivity Dashboard =====
 
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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.
 
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'''Productivity at the Cell level'''
 
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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.
 
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The following are the formulae used to calculate the Key KPIs:
 
 
* Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
 
* Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
 
* Availability = Operating Time / Scheduled Time
 
* Availability = Operating Time / Scheduled Time
 
* Performance = (No. of parts * Ideal cycle time ) / Operating Time
 
* Performance = (No. of parts * Ideal cycle time ) / Operating Time
 
* Quality = (No. of good parts / Total parts produced ) * 100
 
* Quality = (No. of good parts / Total parts produced ) * 100
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The dashboards also display also following set of KPIs: Capacity Utilization, Uptime, Planned Downtime and Unplanned Downtime.
 
  
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The following are the formulae used to calculate the KPIs:
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'''2) CU''' - Capacity Utilization (CU) is the extent to which an enterprise or a nation uses its installed productive capacity.
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* Effective Working Time (EWT) = Total available time - Planned maintenance
 
 
* Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT
 
* Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT
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'''Productivity at the Line level'''
 
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A production line is a series of process steps, where the form fit or function is changed at each step to produce a product.
 
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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.
 
−
 
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The following are the formulae used to calculate the Key KPIs:
 
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* Overall Equipment Effectiveness (OEE) = Availability * Performance * Quality
 
−
* Availability = Operating Time / Scheduled Time
 
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* Performance = (Actual Production/Line Speed) / Operating Time
 
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* Quality = (No. of good parts / Total parts produced ) * 100
 
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The dashboards also display also following set of KPIs: Capacity Utilization, Uptime, Planned Downtime and Unplanned Downtime.
 
−
 
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The following are the formulae used to calculate the KPIs:
 
 
* Effective Working Time (EWT) = Total available time - Planned maintenance
 
* Effective Working Time (EWT) = Total available time - Planned maintenance
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* Capacity Utilisation (CU) = (EWT – Planned Shut Down Time - No Demand) / EWT
 
  
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In the dashboard, the next section explains about the Production Quality and Production Losses.
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'''3) EU''' - Effective Utilization = Overall equipment effectiveness (OEE) * Capacity Utilization (CU)
  
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'''Production Quality'''
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'''4) Cycle Time''' - Cycle Time is the total time from the beginning to the end of your process including loading, processing and unloading. A Cycle is used to calculate throughput time and mostly used in discrete manufacturing.
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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
 
* Cycle Time = Loading Time + Machine Auto Cycle + Unloading Timeline
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(Quality aspect is discussed in detail in the Quality Module)
 
  
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'''Production Losses'''
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'''5) Downtime''' - Total time for which machine was stopped or the product is not getting produced for a selected shift or a day
  
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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.
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'''6) Planned Downtime''' - Downtime is caused by planned maintenance, operator leave or a holiday.
  
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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
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==== MInt Hierarchy ====
 +
To translate the present organization structure into an IIOT enabled formation; The Datonis MInt application has the following hierarchy.
 +
# Department (Plant)
 +
# Cell or Line (under the plant)
 +
# Workcenter(s) (i.e. machines under a cell or a line)
  
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'''Productivity at Workcenter'''
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=== 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.
  
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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.
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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.
  
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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.
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=== Productivity ===
 +
Productivity is an 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.
  
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'''Demo Video''': https://drive.google.com/file/d/13aebJxH9Q5u72VrUW6romwsLFwMR_tDZ/view?usp=sharing
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Datonis Manufacturing Intelligence portraits productivity in the following manner:
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===== Productivity Analysis for Cell / Line =====
 
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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.
 
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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.
 
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A further drill-down report ‘Workcenter Trend Report’ is also available on click on the workcenter name, which is explained in the next section.
 
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'''Demo Video''':
 
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===== Productivity Analysis for Workcenter =====
 
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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.
 
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'''Demo Video''':
 
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===== Production Timeline View =====
 
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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.
 
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'''Key Slots''': Productive Slots (Green Slots), Unplanned Downtime Slots (Red Slots) and Planned Downtime Slots (Yellow Slots)
 
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A hyperlink is provided for each workcenter to drill down into a workcenter specific productivity dashboard.
 
  
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'''Demo Video''':
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'''Productivity- User Actions''':
  
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===== Loss Analysis =====
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The bookings are added under the Actions menu. The user can perform the following bookings under the productivity module:
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This report is currently under enhancement.
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* Downtime Booking
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* Production Booking
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* Book Performance Loss
 +
'''[[Productivity User Actions|Learn more about Productivity user actions]]'''
  
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===== Workcenter Loss Analysis =====
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'''Productivity Reports''': There are different reports covered under this:
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This report is currently under enhancement.
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* Productivity Dashboard
 +
* Productivity Analysis
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* Production Timeline
 +
* Downtime Analysis
 +
'''[[Productivity Reports New|Learn more about Productivity reports]]'''
  
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==== Condition Based Monitoring Module ====
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=== CBM ===
 
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).
 
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).
  
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Although there are few master data configuration related changes for CBM module. Those have been covered in the MInt Configuration Section.
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'''CBM- User Actions''':
  
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===== CBM Dashboard =====
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'''[[CBM User Actions|Learn more about Machin maintenance]]'''
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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.
 
  
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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.
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'''CBM- Reports''':
 +
* CBM Dashboard at Cell/Line
 +
* CBM Dashboard at workcenter
 +
* MTBF and MTTR Reports at Cell/Line
 +
* MTBF and MTTR Reports at workcenter
 +
'''[[CBM Reports|Learn more about Condition based monitoring reports]]'''
  
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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.
+
=== Quality ===
 +
Quality is another important aspect of production and so as of Datonis Manufacturing Intelligence. The effects of quality bottlenecks can be reflected across the entire line or cell. The continuous efforts to deliver quality products while balancing optimal throughput is an important measure to help manage manufacturing processes. Datonis Manufacturing Intelligence tries to cover the quality aspects of it from the rejection bookings and its impact can be also represented in the application in its reports.
  
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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.
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'''[[Quality Reports|Learn more about Quality reports]]'''
  
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====== Workcenter Maintenance ======
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Datonis Manufacturing Intelligence also has a provision to record quality samples and maintain a digital trace using Inspection Policy module.
  
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'''Demo Video''':
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'''[[Inspection Policy|Learn more about Inspection Policy]]'''
  
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===== Workcenter CBM Dashboard =====
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=== Energy  ===
 +
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.
  
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===== Parameter SPC Report =====
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The following reports are covered under energy workspace:
 +
* Energy Dashboard
 +
* Energy Analysis
 +
'''[[Energy Reports|Learn more about Energy Reports]]'''
  
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===== MTBF and MTTR Report =====
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=== Workorder ===
 +
The Work order is another workspace in Datonis Manufacturing Intelligence. This captures the overall production happened for a Part for the planned work order. This provides a detailed view of the work order progress. Datonis Manufacturing Intelligence also allows creating the Workorder for a Part. Work order also maintains its life cycle in terms of when it is planned vs when it is completed and other aspects of it.
  
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===== Workcenter MTBF and MTTR Report =====
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'''[[Workorders Workspace|Learn more about Workorders]]'''

Latest revision as of 11:14, 6 May 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.

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.

Basic Concepts

Key Definitions

KPI management first starts with understanding what to measure and then how to measure. The Datonis Manufacturing Intelligence has a well-defined measurement to monitor, analyze and optimize the defined production KPIs.

1) OEE - Overall equipment effectiveness (OEE) is a measure of how well a manufacturing operation is utilized (facilities, time and material) compared to its full potential, during the periods when it is scheduled to run.

  • 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

2) CU - Capacity Utilization (CU) is the extent to which an enterprise or a nation uses its installed productive capacity.

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

3) EU - Effective Utilization = Overall equipment effectiveness (OEE) * Capacity Utilization (CU)

4) Cycle Time - Cycle Time is the total time from the beginning to the end of your process including loading, processing and unloading. A Cycle is used to calculate throughput time and mostly used in discrete manufacturing.

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

5) Downtime - Total time for which machine was stopped or the product is not getting produced for a selected shift or a day

6) Planned Downtime - Downtime is caused by planned maintenance, operator leave or a holiday.

MInt Hierarchy

To translate the present organization structure into an IIOT enabled formation; The Datonis MInt application has the following hierarchy.

  1. Department (Plant)
  2. Cell or Line (under the plant)
  3. Workcenter(s) (i.e. machines under a cell or a line)

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.

Productivity

Productivity is an 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.

Datonis Manufacturing Intelligence portraits productivity in the following manner:

Productivity- User Actions:

The bookings are added under the Actions menu. The user can perform the following bookings under the productivity module:

  • Downtime Booking
  • Production Booking
  • Book Performance Loss

Learn more about Productivity user actions

Productivity Reports: There are different reports covered under this:

  • Productivity Dashboard
  • Productivity Analysis
  • Production Timeline
  • Downtime Analysis

Learn more about Productivity reports

CBM

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).

CBM- User Actions:

Learn more about Machin maintenance

CBM- Reports:

  • CBM Dashboard at Cell/Line
  • CBM Dashboard at workcenter
  • MTBF and MTTR Reports at Cell/Line
  • MTBF and MTTR Reports at workcenter

Learn more about Condition based monitoring reports

Quality

Quality is another important aspect of production and so as of Datonis Manufacturing Intelligence. The effects of quality bottlenecks can be reflected across the entire line or cell. The continuous efforts to deliver quality products while balancing optimal throughput is an important measure to help manage manufacturing processes. Datonis Manufacturing Intelligence tries to cover the quality aspects of it from the rejection bookings and its impact can be also represented in the application in its reports.

Learn more about Quality reports

Datonis Manufacturing Intelligence also has a provision to record quality samples and maintain a digital trace using Inspection Policy module.

Learn more about Inspection Policy

Energy

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.

The following reports are covered under energy workspace:

  • Energy Dashboard
  • Energy Analysis

Learn more about Energy Reports

Workorder

The Work order is another workspace in Datonis Manufacturing Intelligence. This captures the overall production happened for a Part for the planned work order. This provides a detailed view of the work order progress. Datonis Manufacturing Intelligence also allows creating the Workorder for a Part. Work order also maintains its life cycle in terms of when it is planned vs when it is completed and other aspects of it.

Learn more about Workorders

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