Difference between revisions of "Datonis Manufacturing Intelligence Beta"

Revision as of 08:31, 15 April 2020

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