You don't have to replace your machines with the new ones to make your production "smarter" and more efficient. Your shop floor is a data mine, and digitization is the key to unlock its value.
Read more_Production Monitoring with OEE
_Revolutionizing Production Monitoring: Success Storie
_The end of the era of out-of-the-box OEE systems?
Gartner predicts that by 2025, up to 60% of manufacturing support systems will be
build-to-order.
The basic OEE system is of limited value. Only the right analysis of the data and use of the collected insights improves the efficiency of the organization. That is why tailoring tools to manufacturing processes and needs provides real value.
Build an OEE system with us - 40% of companies say that solutions built specifically for them have exceeded their expectations.
_Implementation strategy for a tailor-made OEE system
We develop tailor-made applications and IT systems for the industrial sector.
Every step of the process from design through implementation to maintenance, is tailored to the needs of the client organization to improve current production efficiency.
Machine connectivity
We provide appropriate connectivity solution, even for older machines and production equipment, regardless of manufacturer.
Production monitoring with OEE
We customize the system for production and personalize formulas, and the information displayed on screens or in reports.
Process optimization
We use AI/ML engines to support your teams in their everyday decisions to meet business needs and present the insights understandably.
Scaling the solution
We are looking for synergies with other areas, and we move the solution to other production lines and plants.
_How does our OEE system work?
The solution is custom-built, but we can highlight the basic modules:
Monitor production progress and machine condition by calculating production indicators, such as OEE.
Reporting, manual, or automatic categorization of downtime, including changeovers and micro downtime.
Helps troubleshoot and identify bottlenecks based on historical and trending data.
Reports to analyze quality data (defects, waste, losses).
_IT/OT convergence
The process begins with an in-depth discussion with our expert, who carefully assesses the business requirements and proposes a plan of activities.
7 years of experience
More than 1,200 completed projects
Technology adapted to needs, never the other way around Holistic approach from concept to maintenance
Holistic approach from concept to maintenance
_TT PSC's OEE system compared to other solutions
Function
TT PSC
Ready solutions
Easy expansion with changing requirements
TTPSC
Ready solutions
Flexibility to adapt to the customer production process
TTPSC
Ready solutions
Collection and exchange of data from various sources
TTPSC
Ready solutions
Customized and configured metrics (e.g.: OOE, TEEP, MTBF)
TTPSC
Ready solutions
OEE expressed not only in % (e.g., losses in time, pieces of product)
TTPSC
Ready solutions
Adaptation to new production line and plant
TTPSC
Ready solutions
Data security and alignment with company regulations
TTPSC
Ready solutions
Data prepared for AI/ML analysis
TTPSC
Ready solutions
Open access to data and vendor independence
TTPSC
Ready solutions
No hidden costs
TTPSC
Ready solutions
No requirement for dedicated vendor equipment
TTPSC
Ready solutions
Training and consulting in the area of Industry 4.0
TTPSC
Ready solutions
_When is a custom OEE solution the right choice?
Off-of-the-box OEE solutions available on the market are becoming insufficient in the context of organizations' growing needs.
You have an innovative business idea that requires higher production efficiency and it is necessary to join the digital (r)evolution and Industry 4.0.
Now more than ever, it is critical to focus on improving operational efficiency and measuring OEE as competition intensifies.
OEE levels should meet industry standards. You need a solution to make that happen.
_Benefits of custom OEE implementation
Use that foundational data in the digitalization journey
Increase machine efficiency and availability
Raise product quality standards
_What challenge is your company challenge?
See if you can find your company's problems. Find out what the solution is..
- How to reduce energy costs in a manufacturing plant?
Solution
EMS system - Energy Advisor
Energy Advisor measures the energy consumption rate in real-time and conducts an analysis of energy efficiency losses. This makes it possible to identify areas where energy can be saved, minimizing consumption during production.
Read more about our EMS system - Energy AdvisorAsk your advisor about the EMS system
Let's talk - How to avoid production downtime?
Solution
Production Monitoring with OEE
With the application, you can monitor production and productivity in real time, empowering you to make informed decisions based on machine data. The system also facilitates measuring manufacturing productivity by calculating the OEE index, allowing you to evaluate the efficiency of the production process.
Talk to our expert
Let's talk - How to increase production efficiency without investing in new machinery?
Solution
Production Monitoring with OEE
With the OEE calculation application, you keep track of the current value of the OEE indicator and production efficiency, including the OEE score. This capability empowers you to make more accurate decisions by analyzing data from production machines.
Contact our expert
Let's talk - How can you eliminate paper and spreadsheets?
Solution
Paperless
Dedicated software facilitates paperless manufacturing, accelerating internal communication and enhancing decision-making processes. This paperless approach is pivotal in the evolution towards Organization 4.0, particularly benefiting manufacturing companies by minimizing human factors in data management and operations.
Contact our expert
Let's talk - How to improve production quality and reduce costs?
Solution
Predictive Quality Analytics
The solution analyzes process parameters in real time, empowering the identification and diagnosis of quality issues before they manifest in the finished product. Supporting Industry 4.0 principles, it enhances overall production efficiency while mitigating quality defects and identifying quality losses.
Predictive Quality Analytics - check detailsLearn more about this solution
Let's talk - How to predict and reduce equipment failures?
Solution
How to predict and reduce equipment failures?
If you are performing preventive maintenance and still looking for an improvement - Predictive Maintenance enables increased machine availability by analyzing machine parameters in real time, predicting potential issues, and proactively preventing them. This proactive approach reduces overall failure time, promoting stable production and minimizing unplanned downtime.
Learn more about Predictive MaintenanceTalk to an expert
Let's talk - How do I create automated production reporting?
Solution
Production Monitoring with OEE and Paperless
These tools facilitate real-time collection of production data, diminishing operational time and granting access to up-to-date information in different processes across the shop floor. Utilizing them, you can enhance the efficiency of reporting and decision-making through thorough data analysis, benefiting production teams and optimizing manufacturing processes.
Talk to an expert
Let's talk - How to automatically calculate production performance indicators (KPIs)?
Solution
Production monitoring with OEE
Using the production monitoring application, key production performance indicators such as productivity, quality, and machine availability are automatically counted. By monitoring production with OEE, it is possible to continuously track and analyze OEE levels.
Talk to an expert
Let's talk - How to improve communication and data flow?
Solution
Paperless
Digitization eliminates the need for paper documentation, speeding up communication and data flow. Data is stored digitally, reducing operational time and providing immediate access to information for all stakeholders, while increasing efficiency in the use of personnel.
Consultation with an expert
Let's talk - How to reduce CO2 emissions?
Solution
EMS system - Energy Advisor
Energy Advisor empowers the analysis of energy consumption and the identification of areas for reducing CO2 emissions. Additionally, it can calculate CO2 values concerning a product, enabling a more precise assessment of a production facility's environmental impact. This tool is particularly beneficial for addressing poor environmental conditions and fostering sustainability within manufacturing operations.
Read more about our EMS system - Energy AdvisorAsk about the Energy Advisor system
Let's talk - How can you better deal with employee turnover?
Solution
Digital Work Instructions
With digital work instructions, you'll ensure consistency and accessibility of information, irrespective of employee experience. This accelerates the learning curve for new crew members, mitigating the negative impacts of turnover. Additionally, digital instructions facilitate minimizing operator errors, while also optimizing operations towards achieving maximum speed of production teams.
Could you contact our expert
Let's talk
_Feedback from our customers
The TT PSC team showed strong technical expertise and motivation while working on the project.
We are grateful for their flexibility and help in finding a solution that meets our business goals. The new IIoT reporting platform based on ThingWorx developed by TT PSC helped us simplify data monitoring and analysis for our customers. We are positive that we will successfully continue to work with TT PSC in the upcoming Product Development Roadmap.
Preben Alstrøm
Digital Solutions & Science Director
Haarslev
Thanks to Real-Time-Monitoring, we can now quickly identify information on incidents and report them back,
so that the operator can independently analyze the incident and correct it with as little disruption to production as possible. Working with TT PSC we achieve our goals faster and more effectively than expected.
Emmanuel Thommerel
VP IT
Lacroix
_Related articles
In the manufacturing industry, efficiency is key to staying competitive and profitable. One way to improve efficiency is through data visibility. By having access to real-time visibility of the operational data throughout the manufacturing process, companies can identify bottlenecks, monitor production lines, and make data-driven decisions. In this article, we'll explore how data visibility can help manufacturing companies improve their efficiency and ultimately their bottom line.
Read more_Frequently asked question
OEE definition - OEE (Overall Equipment Effectiveness), stands as a cornerstone metric within manufacturing operations, offering a comprehensive evaluation of the efficiency of equipment and production lines. It amalgamates three factors (performance score, quality score, availability score) to identify what is the percentage of truly productive manufacturing time.
Availability assesses the time equipment is available for production compared to its planned production time, accounting for factors like downtime and changeovers. Performance scrutinizes the speed at which equipment operates about its optimal capacity, revealing potential inefficiencies or slowdowns. Quality measures the ratio of good output to total output, identifying any defects or rework that may impact overall productivity.
A good OEE score is considered to be between 65-85%, whereas above 85% is considered world-class.
The OEE is one of the main manufacturing metric, essential for evaluating manufacturing operations, encompasses the calculation of availability, performance, quality scores, effectively capturing the equipment's operational efficacy.
- Availability losses - the time of unplanned events, such as downtime. Availability loss therefore is not planned maintenance to perform maintenance tasks.
- Performance losses - all events that causes decrease in the cycle time. Exemplary performance loss is when equipment runs slower due to lack of clear and easily accessible operation instructions, substandard materials or material jams, slow cycles.
- Quality losses - production rejects or defective units.
To calculate OEE, you need to consider three components: Availability (%) x Performance (%) x Quality (%), which together contribute to the overall OEE score. This meticulous OEE calculation process helps in assessing manufacturing productivity accurately, ensuring a comprehensive understanding of operational efficiency and performance.
- Availability - divide the actual production time to planned production time. It relies on operating time (not including planned downtimes), therefore planned downtimes does not cause availability loss.
- Performance - divide the throughput by maximum throughput that is possible.
- Quality - the percentage of good units to total count. Production rejects decrease the quality score.
While OEE focuses on Overall Equipment Effectiveness, encapsulating Performance, Quality and Availability component, efficiency typically denotes the optimal utilization of resources to achieve production goals.
Simplifying, an 85% OEE signifies that the manufacturing equipment operates at 85% of its maximum potential, factoring in Availability, Performance, and Quality metrics, thereby indicating room for improvement in production efficiency.
By the way, 85% is considered the world-class OEE.
OEE, an acronym denoting Overall Equipment Effectiveness, holds paramount significance within manufacturing contexts, facilitating the assessment and enhancement of operational efficiency.
Do not confuse OEE with TEEP (total effective equipment performance), which is a metric to display the performance of an entire production line or plant in the scope of all productive time (including scheduled losses, such as when production is not planned).
Current OEE score allows you to understand the efficiency of your equipment and production in a simple metric. Of course simple calculation it is not enough to present the complex environment of production. But usually it's very good first step to assess the need for deeper analysis. By analyzing OEE you enable identifying losses and performing root cause analysis, allowing to uncover underlying issues and possible improvements.
It is also one of the key metrics for total productive maintenance and a broader lean manufacturing methodology.
Calculating the OEE of multiple machines necessitates the individual assessment of Availability, Performance, and Quality metrics for each machine, followed by aggregation to derive comprehensive insights into manufacturing productivity across the entire spectrum.
Availability is computed by dividing operating time by planned production time, Performance entails evaluating actual production speed against maximum theoretical speed, while Quality is assessed by scrutinizing the ratio of good units produced to total units manufactured.
Real-time OEE measurement offers the distinct advantage of providing up-to-the-minute insights into production efficiency within the manufacturing process. By continuously monitoring performance metrics such as availability, performance, and quality, businesses can promptly identify bottlenecks, minimize downtime, optimize resource allocation, and implement timely improvements to enhance overall equipment effectiveness and operational efficiency.
This proactive approach ensures that any issues are swiftly addressed, leading to improved productivity, reduced costs, and increased profitability over the long term.
Production monitoring is a process of continuous, real-time data acquisition from equipment and manufacturing process. It allows to:
- Understand current status of your production
- Spot issues and bottlenecks and resolve them faster
- Optimize the production and equipment performance
One of the most imporant aspects of production monitoring is to enable more proactive approach to manfuacturing.