What is Performance Metrics in SFactrix MES?
Performance Metrics is defined as the representation of the quantitative measure of parameters over a period of time concerned with the operations in any industry. The manufacturing metrics enable the factory user to make quicker decisions and necessary corrections to improve production performance, efficiency, and quality.
How many manufacturing metrics are available in SFactrix MES?
Manufacturing metrics at the shift level are calculated based on the operations data collected from the operator through the production controller or operator kiosk. There are 3 different types of metrics are available on SFactrix.
Assets Performance Metrics
Maintenance Metrics and Fault Trends
Quality Metrics and Rejection Trends
Pre-Condition: Plant, Assets, Parts, Manufacturing order, and Work Orders should be created in prior to exploring metrics. There should be an active work order and the asset operations such as start, stop, break and fault performed accurately on the asset control corresponding to the machine operations in the Plant. The exact total production count and rejection count should be entered to generate accurate and meaningful live data metrics in SFactrix. Accurate shift hours should be entered at the plant level, as the metrics will be calculated as shift hours based.
Steps to view the metrics page:
Go to 'Metrics' menu available on the menu bar.
The metrics page is displayed with default to asset performance-based metrics for default assets.
How to view Assets Performance Metrics on SFactrix?
Assets metrics are available based on shift hours from current shift to Today, last 7 Days, and last 30 days periods for easy comparisons and quicker decision-making. Two types of metrics are available at the assets level,
Performance-based data metrics display the metrics of an asset that carries the statistics related to the performance and efficiency of the asset productivity. The efficiency and productivity of an asset are the key components of an industry. Hence it is important to keep a track of the parameters influencing efficiency and productivity. The data used for the calculations are based on the actions performed on the production controller.
Follow the below steps to view the Performance-Based metrics.
Go to the 'Metrics' page available on the menu bar.
Click the 'Assets' tab on the metrics page.
Choose a shift hour as (Current Shift/ Today/ last 7 days/ last 30 days).
Choose an asset from the drop-down list to view the metrics.
Choose the metric type as 'Performance-based' from the drop-down list.
The performance data metrics pertaining to the asset chosen and the type of metrics will be auto-generated on the metrics page.
There are 8 parameters of 'Performance based' data metrics calculated for current shift hours, and 4 parameters calculated for daily, 7 days, and 30 days metrics. The details of each parameter are listed below.
Card 1 displays the Efficiency of the production of an asset. Efficiency can be defined as the total quantity produced by an asset to its expected production quantity expressed as a percentage.
Efficiency is calculated with the below formula,
Efficiency = (Good quantity/ ideal part count) * 100
Card 2 displays the Slow Cycle (in mins) per asset. When the asset does not meet the expected quantity of production and time wasted in producing the expected quantity is known as Slow Cycle time.
For example, when the asset is scheduled to produce 10 units per min and the asset produces only 8 units per min, the time wasted in producing (10-8=2) the 2 units is called Slow Cycle.
Slow Cycle time is calculated with the below formula:
Asset Slow Cycle time = (ideal part count * Part lead time) - (total Qty count * Part lead time)
Card 3 displays the Good Count. Good Count can be defined as the number of good quality products produced (products that pass the QC test) for the current period.
Good Count is calculated with the below formula:
Good Count = Total Quantity produced - Rejection Count
Card 4 displays the Rejection count produced by the asset chosen. Rejection Count can be defined as the number of products which does not pass the Quality Check (QC) test/user's specifications. Rejection Count data fed by production controller by operators.
In the current shift, asset performance-based metrics compare today’s performance value with the previous day’s value and generate the percentage difference through the upward and downward arrows. This represents the rise and drop in today's performance value when compared to the previous day.
Comparative Performance Metrics in SFactrix:
SFactrix Metrics module provides comparative metrics for the production performance for each shift and between the same shifts within the day. Also, the OEE comparative metrics are available between the days.
Go to the 'Metrics' menu available on the menu bar.
Each card on the metrics page displays asset performance-based metrics along with comparative values for default assets.
The highlighted values with arrows upward and downward represent the rise and drop in today's performance value compared to the previous day's value.
The current shift also shows the hourly production performance metrics report through a graph that appears on the metrics page. This hourly shift report helps the users to identify the continuous performance data of running assets.
Let's move into Today's metrics. 'Today' metric is the consolidation performance for each shift hour. Today's metrics also show OEE, Performance, Availability and Quality metrics at each shift level.
OEE (Overall Equipment Efficiency) measures the utilization of the asset to its peak utilization capacity during its scheduled time of operation.
OEE is calculated with the below formula:
OEE = Availability * Performance * Quality/100.
The below image shows the Performance-based calculations of OEE for today's shifts.
Performance metric measures the performance data of the asset chosen. Performance can be expressed as a percentage of the expected speed of production to the actual speed.
Performance is calculated with the below formula,
Performance= (lead time * total quantity *100) / run time in mins.)
Availability Metrics display the availability of the asset of each shift within the day. The availability of machine is calculated based on the actual machine running hours for each shift.
Availability calculation formula:
(Runtime*100) / (Runtime + planned downtime + unplanned downtime)
The final one is the Quality production of an asset. When the quantity produced passes the QC (Quality Check) test, then it is said to be a good quality product. Else, the product will be termed as a rejection count. Quality is expressed as a percentage of the number of quality products to the total products manufactured.
Quality is calculated with the below formula:
Quality = (good quantity*100) / total quantity)
The above image shows the live calculations of Quality for today and indicates that 96% of the products manufactured by the asset are good-quality products.
What is "Time Based" metrics in SFactrix MES?
Time-based assets metrics display the graph based on the time (in mins) of operations of an asset working in the manufacturing industry. These metrics are drawn from data related to the time of operations of the asset (Runtime), asset's start time, end time, break time, fault time, scheduled time for production, etc.
The time-based metric is available for the shift hours Today, last 7 days, last 30 days.
Follow the below steps to view the Time based metrics.
Go to the 'Metrics' page available on the menu bar.
Choose an asset of which the data metrics are to be viewed from the drop-down list.
Choose the option 'Time Based' from the 'Choose metrics type' drop-down menu.
There are two data metrics available on the 'Time-based' metrics. The details of each tile are listed below.
Card 1: Displays the Runtime vs Downtime of the asset selected.
Runtime in industrial terms means the actual time when the machine is running.
Downtime is referred to the time when the machine is not working or not available for production although the production is scheduled.
Downtime can be classified as Planned Downtime and Unplanned Downtime.
Planned Downtime refers to the scheduled breaks taken by the workers during shift hours like lunch breaks. Time is recorded when you click 'Break' on Asset Controller.
Unplanned Downtime refers to faults and unplanned events such as machine failure, time taken for the machine setup, tool adjustments, etc. Time is recorded when you click 'Fault' on Asset Controller.
OOS (out of shift) refers to asset status during an unscheduled shift.
The below image shows the graph Runtime vs Downtime of the asset for today.
Green bar indicates the Runtime i.e. when the asset is 'Running' state.
Yellow bar indicates the Planned Downtime when the asset is in a 'Break' state.
Red bar indicates the Unplanned Downtime when the asset is in the 'Fault' state.
OOS(out of shift) graph bar indicates assets' runtime, planned and unplanned downtime during Out of Shift hour.
Card 2: Card 2 displays Planned Production vs Schedule Loss of the asset selected.
Planned Production Time is defined as the scheduled time of the machine for production in each shift hour.
Schedule loss is the time loss that occurs when the machine is not producing the quantity of product even though it is in running state. This can be due to materials unavailability, operator unavailability or other reasons.
The below image shows the graph Planned Production vs Schedule Loss for today.
The green bar shows the time (in mins) the asset is involved in production.
The yellow bar indicates the time (in mins) when the asset is not involved in production.
Bar OOS (Out of Shift) indicates the planned and unplanned production during unscheduled shift hours.
Similar to manufacturing Assets metrics, SFactrix MES also provides maintenance metrics and Quality metrics that help the factory users to track the fault trend and efficiency in production, and quality trends.
Click the below link to learn about fault or maintenance trend in SFactrix'.
For any feedback and enquires on the functionalities of the metrics write to our support team at [email protected]