OEE KPI Calculation report for discrete manufacturing in SAP Digital Manufacturing.

[sunita_sarkar]

Title: OEE (Overall Equipment Effectiveness)KPI Calculation report for discrete manufacturing in SAP Digital Manufacturing.

Introduction

SAP Digital Manufacturing provides important feature to create OEE KPI Calculation report for discrete manufacturing in SAP Digital Manufacturing. In SAP DM ,OEE is a matric which is measuring manufacturing performance . You can calculate the overall equipment effectiveness (OEE) using the Availability, Performance, and Quality Key Performance Indicators (KPIs). OEE metric measures availability and performance of equipment and the quality of goods produced by that equipment. OEE allows to measure and analyze plant performance both in real-time and historically and OEE utilizes common sources of manufacturing data to obtain metrics.

OEE is defined as the product of three KPIs:

Overall Equipment Effectiveness (OEE) = Availability X Performance X Quality

Here we are considering a short definition of the input parameters:

• Availability-The ratio of the amount of time a resource was productive to the amount of time the resource was expected to be productive.
• Performance-The ratio of the amount of time needed to produce good and bad quality items to the amount of time that would have been needed to produce these items based on the designed speed.
• Quality-The ratio of time needed to produce good quality products to the total number of quantities produced (yield and scrap).

Availability KPI

The Theoretically Available Time of our resource is 9 hours. There's one scheduled down of 1 hour planned during the shift. Moreover, because of an operator's mistake, the resource is down for 2 hours.

• Theoretically Available Time = 9 hours
• Loading Time = 9 hours - 1 hour (scheduled down) = 8 hours
• Running Time = 8 hours - 2 hour (unscheduled down) = 6 hours

Availability KPI Formula

• Availability = Running Time / Loading Time x 100%
• Availability = 6 hours / 8 hours x 100% = 75%

Performance KPI

The main purpose of the Performance KPI is to compare the actual production speed to the designed production speed.

The Total Production Time is 10 hours. During this time, there's one unscheduled down of 1 hour and one scheduled down of 1 hour. The designed speed (standard rate) is of 1 item per hour. The target quantity for the 8 hour shift is 8 items. During the shift, the actual production quantity is of 6 items (yield and scrap).

Total Production Time = 10 hours

Net Production Time = Total Production Time - Downtime = 10 hours - 2 hours = 8 hours

Net Operating Time = Actual Quantities Produced (yield and scrap) x Standard Rate = 6 x 1 = 6 hours

Speed Loss = Net Production Time - Net Operating Time = 8 hours - 6 hours = 2 hours

Performance = Net Operating Time / Net Production Time x 100%

E.g. Performance = 6 hours / 8 hours x 100%= 75%

Quality KPI

The Total Production Time is 10 hours. During this time, there's one unscheduled down of 1 hour and one scheduled down of 1 hour. The designed speed (standard rate) is of 1 item per hour. The target quantity for the 8 hours shift is 8 items. During the shift, the actual production quantity is of 6 items (yield and scrap), of which 4 meet the quality standards.

Total Production Time = 10 hours

Net Production Time = Total Production Time - Downtime = 10 hours - 2 hours = 8 hours

Net Operating Time = Actual Quantities Produced (yield and scrap) x Standard Rate = 6 x 1 = 6 hours

Speed Loss = Net Production Time - Net Operating Time = 8 hours - 6 hours = 2 hours

Quality Loss = (Actual Quantity - Quality Output) x Standard Rate = (6 items - 4 items) x 1 hour / item = 2 hours

Value Operating Time = Net Operating Time - Quality Loss = 6 hours - 2 hours = 4 hours

Quality = Value Operating Time / Net Operating Time x 100%

Quality = 4 hours / 6 hours x 100%= 66,6%

Here we are considering the Work Center POD and Line Monitor POD .Line Monitor POD is using to display OEE report and WC POD is using to execute the SAP DM manufacturing on Discrete Industry .

SAP DM Execution:

We are considering the below SAP Digital manufacturing execution steps for discrete industry.

1. WC POD
2. SFC Start
3. Data collection
4. Create Downtime
5. SFC Complete
6. LM POD open and check OEE calculation
7. Another SFC Start
8. Nonconformance
9. Scarp the SFC
10. Again, LM POD open and check OEE calculation

Pre-requisites:

We are considering the below apps and activities.

1. Work Center POD
2. Line Monitor POD
3. Manage OEE Time Model Configuration App
4. Manage OEE Reason Codes App
5. Assign OEE Reason Codes App
6. Manage Standard Rates App
7. Manage Resources App

Configuration Steps:

The following are the required configuration steps to use OEE:

1. Define Work Center and Resources
2. Assign Resource Status to Time Element Types
3. Define Time Elements and Assign to Time Element Types
4. Define Reason Codes and Assign to Time Elements
5. Assign Reason Codes to Resources
6. Define Standard Rates at Resources
7. Define Shifts and Assign to Resources

Step 1- Assign resource status to OEE time element types.

The resource status behavior should affect the OEE KPI calculation by mapping the relevant resource statuses with OEE time element types.

OEE time element types are pre-delivered. A default mapping of these time element types to resource status is also pre-delivered.

Manage OEE Time Model Configuration app

Time Elements - Time elements help in analyzing losses at various levels and help to classify the losses which form the root node of the reason code hierarchy.

At first define Time Element and then assign it to Time Element Type. You can create a new time element (for example define time element ID UNSCD_<your ID> for the time element description Unscheduled Down) and assign it to the time element type and after mapping time element to time element type, and the time element is used for tagging, you must not change the time element.

You can assign time elements to Scheduled Down (SCHED_DOWN), Unscheduled Down (UNSCD_DOWN), Speed Loss (SPEED_LOSS), and Quality Loss (QUAL_LOSS).

Create Time Elements –Click on Add button and provide the Time Element ID and Description and Save it.

Click on the Time Element Type ID like  SCHED_DOWN and assign the Time element for SCHED_DOWN

Click on Manage Assignment button.

Check and Save

Add the Time Elements if elements are not available. If Time elements are enabled then you can assign to Time Element Types

Step 2- Manage OEE Reason Codes app

Define the reason code and assign to the Time Elements

Select the  row and add reason code

Step 3-Assign OEE Reason Codes App

Click on Assign and assign the reason code to the Resource.

Step 4-Define Standard Rates at Resources -Manage Standard Rate App

Click on Add button and give the values

Step 5-Define KPI Targets at Resource Level

Specify target values of the OEE KPIs to determine a KPI's state, whether green, yellow, or red, at a resource.

By default, the target values of the OEE, Availability, Performance, and Quality KPIs at a resource are defined as 70, 90, and 100. As per the requirement, you can enter custom target values for the KPIs in the Custom Data section of the Manage Resources app. Custom values override default values.

Manage Resources App - By default, the target values of the OEE, Availability, Performance, and Quality KPIs at a resource are defined as 70, 90, and 100

SAP DM Execution:

We are considering the below SAP Digital manufacturing execution steps for discrete industry.

1. WC POD
2. SFC Start
3. Data collection
4. Create Downtime
5. SFC Complete
6. LM POD open and check OEE calculation

Step-I – Start the SFC

Open the WC POD and start the sfc.

Click on Start button to start the SFC

Step-II - Perform the data collection

Click on the Data Collection List Activity and then click on the Collect button.

Collect the data as Boolean value and click on Save button

Once performed the data collection

Step-III- Create Down Time

Click on Downtime Activity

Click on Create Downtime button.

Select Resource and resource status

Select Reason Code

Give Start time ,End time , comments and click on Save button.

Step-IV – SFC Complete

Now complete the SFC. Click on the Comple button.

SFC is completed

Step-V Open LM POD to check OEE report

Asset details

OEE details

Similarly Start another SFC and Scrap the sfc using scrap nonconformance code and check OEE report.

Start  SFC

Click on Nonconformance activity and Scrap the sfc

Check OEE report

Conclusion

In conclusion, OEE KPI Calculation report is playing as an important key role for discrete manufacturing in SAP Digital Manufacturing. Using OEE matric, you can measure manufacturing performance . You can calculate the overall equipment effectiveness (OEE) using the Availability, Performance, and Quality Key Performance Indicators (KPIs). OEE allows to measure and analyze plant performance both in real-time and historically.

If you have any questions, please share your comments on answer questions section and any feedback is highly appreciated.