When material is created using the OEE Material Manager and associated to a production line, operations and process segments for changeover and production as well as an operation definition are automatically created in the background. The production operations segment has complex properties called Production Settings that store information that determines how OEE data is captured and calculated. 

These production and changeover settings can be set using the OEE Material Manager component as well as through scripting

 

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Changeover Settings

The Changeover Settings panel allows you to define what mode the line goes into at the beginning of a production run. 

Idle Mode

Any of the default Idle Modes (Disabled, Changeover, Idle, Maintenance, Production, Other) or custom modes that you have created are valid options. This field defaults to the original Default Idle Mode. If that no longer exists, it will choose the first Idle mode found, alphabetically).

Changeover Mode

Any of the default Equipment Modes (Maintenance, Changeover, Disabled, Production, Other) or custom modes that you have created are valid options. Modes have options for whether production counts are captured or included in OEE. You can use this mode to determine if you want to capture counts, i.e. for setup scrap, but not include it in OEE metrics for this production run.

Changeover Duration (seconds)

Duration in seconds for the scheduled changeover until this run may start.

Auto End Changeover

Set this to True to end the changeover automatically after the scheduled changeover duration. If this is set to false, the selected Changeover Mode will persist until such a time as the tag value provided for the Mode tag collector path in the OEE Downtime 2.0 Tab is written to.




Production Settings

Production Mode

Any of the default Equipment Modes (Maintenance, Changeover, Disabled, Production, Other) or custom modes that you have created are valid options. Modes have options for whether production counts are captured or included in OEE. You can use this mode to determine if you want to capture counts  or obtain OEE metrics for this type of run, i.e. New Product Introduction or Testing.

Changeover Overrun

If you want to automatically capture 'Changeover Overrun' as an OEE metric, this can be achieved in the following way...

  1. Create a Mode called Changeover Overrun
  2. Set Auto End Changeover to True
  3. Set the Production Mode to your Changeover Overrun mode
  4. When Production actually starts, set the Mode Tag (e.g. via system.mes.addTagCollectorValue(eqPath, 'Equipment Mode', '', dateTime, value)) to the value configured for Production Mode

Rate Period

The period of time that applies to all rate values (Standard and Schedule Rate). Valid options are Hours or Minutes.

Schedule Rate

The realistic production rate that this line can be expected to produce at.

Accepting that there will be some downtime on a line and a certain amount of rework or scrap, the Schedule Rate can be set to be the Standard Rate * Historical OEE of this line to provide a more realistic estimation of how long it will take to complete a production run. The Schedule Rate is used by the Scheduler to estimate completion time based on required quantity.


OEE Standard Rate

The standard rate defines the number of units that theoretically can be produced when the line is running. It is also used internally to generate an Infeed Standard Count value that depicts how many units should have been started for the amount of time the line has been running.

Infeed Standard Count is calculated as OEE Standard Rate x Run Time x Package Count.

Although the infeed count is used to calculate OEE Performance, the Standard Rate value should be based on the outfeed units. In other words, how many units, whether individual or packaged, does the line generate over a given period of time. Consider the example when the infeed count is in bottles and outfeed count is in cases with a package count of 10 bottles per case. If the OEE Standard Rate is set to 100 per hour, 1000 bottles must have been counted at the infeed after one hour of runtime for OEE performance to equal 100%. Alternatively, if no infeed count was provided, a combination of 90 cases of good product and 100 rejected bottles must be counted after one hour of runtime, to also equal 100%.

It is possible to configure a production line with a number of combinations of Infeed, Outfeed and Waste count tags. The OEE Performance calculation will be based on which tags are provided.

OEE Rates are stored as "per minute"

The Sepasoft OEE module always stores rates (including the Standard Rate) in "per minute" equivalent, in order to streamline functionality (regardless of the units set in GUI-based components such as the OEE Material Manager). However, when utilizing the Tag Collector, you are storing values directly to the database, so you must convert the values to "per minute" before writing values to these tags. Rate values in the Value Editor will also be "per minute".


InfeedOutfeedWasteOEE Performance Calculation Based on provided tagsComment
(error)(error)(error) n/a
(error)(tick)(error)= (Outfeed Count * Package Count ) / Infeed Standard Count
(error)(tick)(tick)= ((Outfeed Count * Package Count) + (Waste Count * Reject Count Scale)) / Infeed Standard Count
(tick)(error)(error)= (Infeed Count * Infeed Count Scale) / Infeed Standard Count
(tick)(error)(tick)= (Infeed Count * Infeed Count Scale) / Infeed Standard Count
(tick)(tick)(error)= (Infeed Count * Infeed Count Scale) / Infeed Standard Count
(tick)(tick)(tick)= (Infeed Count * Infeed Count Scale) / Infeed Standard CountIf no infeed count tag is provided or the infeed count value does not change during a production run, the outfeed and waste count values will be used.



General Rules for MES Counter Placement

The following guidelines will help users create and assign MES Counters to get the best results for OEE calculation behavior:

  • When there is only one type of MES Counter for the Line (either just an Infeed counter or just one or more Outfeed counters), it/they must be created on the Line in the Production Model. Having only one counter, created on a Cell in the Production Model, does not allow the Line OEE calculations to be calculated correctly.

  • When there is both an Infeed counter and an Outfeed counter (both on the Line, both on Cells, or a mix), make sure that the Infeed Count Equipment and Outfeed Count Equipment in the Material Definition both point to the locations where the MES Counters were created in the Production Model.

Refer to Production Counter Assignments for details on production counter placement and the effects on OEE metrics.



Infeed Count Equipment

The equipment that provides the infeed count for the line. Available options are the line itself or any cell on the line. The Infeed Count value comes from the tag associated with the line or cell as defined in the Production Model Designer. See MES Counters page for more details.


Infeed Count Scale

The Infeed Count Scale is a float value that provides a mechanism for scaling the value of the infeed count tag to the actual number of infeed units.

Imagine a scenario where we are counting strokes on a stamping press for our infeed count, but the number of parts created by the stroke is dependent upon the die set in the press or the product that is being made. 

Example

Infeed Count Scale is set to 5. For each infeed count, the number of infeed units recorded by the OEE module will increment by 5.

This is similar to the Reject Count Scale for the Reject Count

Infeed Units

The units for the infeed count can be specified here. This could be Cans, Bottles etc.

Reject Count Scale

The Reject Count Scale is a float value that provides a mechanism for scaling the value of the reject count tag to the actual number of reject units created.

Imagine a scenario where the reject count is for a pallet or case of product, but the number of parts on the pallet or case is dependent upon the product that is being made. 

Example

Reject Count Scale is set to 24. For each reject count, the number of rejected units recorded by the OEE module will increment by 24.

This is similar to the Infeed Count Scale for the Infeed Count

Reject Units

The units for the reject count can be specified here. This could be Cans, Bottles, Cases, Pallets etc.

Care needs to be taken on how waste is counted. By default waste is considered to be in the same units as the infeed count, so in OEE calculations, it is divided by the Package Count. If the waste value provided is in fact in the same units as the outfeed count units (cases, for example) then the waste count must be multiplied by the same value as the package count. The reject count scale setting can be used to handle this.

Outfeed Count Equipment

The equipment that provides the outfeed count for the line. Available options are the line itself or any cell on the line. The outfeed count value comes from the tag associated with the line or cell as defined in the Production Model Designer. See MES Counters page for more details.

Package Count

The Package Count is a float value that provides a mechanism for associating the value of the outfeed count to the value of the infeed count. It is only used internally to calculate OEE values and does not modify the infeed, waste or production counts. Those are recorded as set up.

Examples

  • Infeed count is in bottles and outfeed count is in cases. For a particular product, there are 24 bottles per case. For this example, we would set Package Count to 24.
  • Infeed count is in lbs and outfeed count is in cans. For a particular product, there are 12oz in each can. For this example, we would set Package Count to 0.75.
  • Infeed count is in lbs and outfeed count is in cans. For a particular product, there are 22oz in each can. For this example, we would set Package Count to 1.375.


Care needs to be taken on how waste is counted. By default waste is considered to be in the same units as the infeed count for OEE calculations. If the waste count value provided is in the same units as the outfeed count units (cases, for example) then the waste count must be multiplied by the same value as the package count. The reject count scale setting can be used to handle this.

Outfeed Units

The units for the outfeed count can be specified here. This could be Cans, Bottles, Cases, Pallets etc.

Auto End Production

When set to True, if Track Production By is set to Schedule (production), the production run will automatically be ended once the desired number of units have been produced. If Track Production By is set to Schedule (time), the production run will automatically be ended once the elapsed time is equal to the scheduled time.

When set to False, the run must be ended using the Run Director or Schedule Selector components, or through scripting functions.

Track Production By

Setting this to Schedule (production) will track the production by the scheduled production rate. Setting the property to Schedule (time) will track the production by scheduled time.

The MES Schedule View Component has a progress bar that will update according to the Track Production Setting. If set to Schedule (production), the progress bar will display as a percentage of current outfeed / Scheduled Qty. The schedule estimated completion time will update every minute to extend the duration of the scheduled run if production is falling behind schedule. If set to Schedule (time), the progress bar will display as a percentage of Elapsed Time / Scheduled Time.

Valid options are:

  • Schedule (production)
  • Schedule (time)


If you want the scheduler to update the estimated completion time at an interval greater than a minute, this can be achieved using the MES Object Editor to change the Update Interval for the operation.



Changing Production Settings Through Scripting

Settings may be changed through the OEE Material Manager component in the designer. However, in the case of an ERP integration, you may want to change the settings through scripting. Here is an example of setting the OEE Rate (a.k.a. Standard Rate) through scripting.

Changing Production Settings Programatically
##Load the Operation Definition based on the Operation Definition Name
opDefName = 'PC01-Enterprise:Site:Area:Line 1'
obj = system.mes.loadMESObject(opDefName, 'OperationsDefinition')

##Load the Operations Segment for Production
opSegUUID = obj.getComplexProperty('SegmentDependency', 'Production Dependency').getSegmentRefUUID()	
opSeg = system.mes.loadMESObject(opSegUUID)

##Iterate through the Production Settings for the Operation Segment.
##For each production setting (i.e. for each line, cell, cell group, etc.) set the OEE Rate
count = opSeg.getComplexPropertyCount('ProductionSettings')
for i in range(count):
	prodSet = opSeg.getComplexProperty('ProductionSettings', i)
	prodSet.setOEERate(78.6)
	opSeg.setPropertyValue('ProductionSettings', prodSet)

##Save the Operation Segment to make the changes manifest
system.mes.saveMESObject(opSeg)
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