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Overview

The time-loss model discussed in the Introduction is implemented by open source projects hosted on GitHub. The parent project is the OEE Designer. From the latest release, download the Point 85 OEE Getting Started and Point 85 OEE User Guide documents for more details.  The binary code is in the oee-<version>.zip file on this page.

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The Point 85 OEE applications enable:

  • Collection of equipment data from multiple sources to support OEE calculations or general purpose data acquisition

  • Resolution of a collected data value into an availability reason or produced material quantity to provide input to the performance, availability and quality components of OEE

  • Calculation of the OEE key performance indicator for the equipment using an optional work schedule for defining the scheduled production time

  • Monitoring of equipment availability, performance and quality events

Data Collection

Sources of equipment availability, performance and quality event data include:

  • Manual: web browser, Android app or iOS app data entry

  • OPC DA: classic OLE for Process Control (OPC) Data Acquisition (DA)

  • OPC UA: OLE for Process Control Unified Architecture (UA)

  • HTTP/S: invocation of a web service via an HTTP/S request

  • RMQ Messaging: an equipment event message received via a RabbitMQ message broker

  • JMS Messaging: an equipment event message received via a JMS message broker

  • MQTT Messaging: an equipment event message received via an MQTT message server

  • Kafka Messaging: an equipment event message received via a Kafka message server

  • Web Socket Messaging: an equipment event message received via a web socket server

  • Email: an equipment event message received via an email server

  • Database Interface Table: a predefined table for inserting OEE events from a relational database

  • File Share: a server hosting OEE event files

  • Modbus: a Modbus master communicating with its slaves.

  • Cron Job: a cron job scheduled to execute at specified points in time

  • GE Proficy Historian: a historian collecting tag data

Applications

The Point85 applications supporting OEE are:

  • Designer: a desktop GUI application for defining the plant equipment, data sources, event resolution scripts, manufacturing work schedule, availability reasons, produced materials and units of measure for data collectors. The designer also includes a dashboard and trending capabilities.

  • Collector: a headless Windows service or Unix deamon to collect the equipment event data and store it in a relational database

  • Monitor: a desktop GUI application with a dashboard to view the current equipment OEE and status

  • Operator: a desktop GUI application for manual entry of equipment events

  • Operator Web: a web-application for manual entry of equipment events

  • Operator Mobile iOS App: an iOS application for manual entry of equipment events

  • Operator Mobile Android App: an Android application for manual entry of equipment events

In addition, two GUI test applications assist in the development of an OEE solution:

  • Tester: a desktop HTTP requester and a message publisher

  • Test Collector: a desktop UI front-end for a data collector

 

The data for calculating OEE can be entered manually (for example at the end of a shift) or be collected from a data acquisition system event from one or more of the above data sources. For manual data collection the data can be summarized over a period of time (e.g. a shift) or entered as the events occurred. Collecting data at the event level allows for Mean Time Between Failure (MTBF) and Mean Time to Repair (MTTR) calculations.

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The diagram below is an overview of the system architecture:

system-architecture.png

The OEE applications can be grouped into design-time and run-time. The design-time Designer application is used to define the plant equipment, data sources, event resolution scripts, manufacturing work schedule, availability reasons, produced materials and units of measure for data collectors. The designer also includes a dashboard and trending capabilities.

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​An automated run-time data collector receives an input value from a data source source and executes a JavaScript resolver on this input to calculate an output value. The output value is a reason (mapped to an OEE loss category) for availability or performance events, a new production count (good, reject/rework or startup) for quality events or a material/job change event. For the case of a custom event, the output value is ignored.

The event data is stored in a relational database using the Java Persistence API (JPA) where it is available for OEE calculations. Microsoft SQL Server, Oracle, MySQL, PostgresQL and HSQLDB are currently supported.

 

A mobile or web-based manual data collector running in a web server records the OEE events based on information entered by an operator. Similar to the automated collector, this data is also stored in the relational database.

 

If the system is configured for messaging, the event data is also sent to a RabbitMQ, JMS, MQTT or Kafka message broker to which a run-time monitor application can subscribe. A monitor displays a dashboard for viewing equipment OEE events. It also displays collector notifications and status information.

Designer Application
designer-plant-entities.png

The Designer configures all aspects of equipment in order to enable OEE calculations. It has editors for defining the plant model, reasons, materials, units of measure and work schedule. 

 

Design-time data can also be backed up and restored or imported from a file.

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The Designer can also display a dashboard for the selected equipment.

The Designer and Monitor have a trending capability to observe the input and output values of a configured data source. In this example, OPC DA.

designer-opc-da-trend.png
Collector Application

The Collector application runs as a Windows service or Unix daemon on the configured host computer. A Collector executes equipment event resolver scripts upon receipt of an input value and stores the availability, production, material or job change event data in the database. This data is used for OEE, MTBF and MTTR calculations.

Monitor Application

The Monitor application has three main functions, to observe:

  • Equipment performance via metrics available in the dashboard.

  • Notifications from the data collectors for abnormal conditions

  • Data collector status.

 

An example of dashboard tiles is:

dashboard-tiles.png

Production and availability events can be shown in chronological order, for example:

dashboard-events.png

Production and availability events can also be shown in a trend chart, for example:

availability-trend.png

The time-losses tab shows a bar chart of the OEE loss categories:

dashboard-time-losses.png

A first-level Pareto chart show the time losses in percentage terms, for example:

A second-level Pareto displays the reasons for an availability category, for example for Minor Stoppages:

Operator Desktop Application
operator-availability.png

This Operator application is a desktop application that allows a user to enter availability, performance, production, material change and job events. The events can be recorded in chronological order as they happened or in summary form over a period of time by duration of the event.

Operator Web Application

The Operator web application is browser-based and allows a user to enter availability, performance, production, material change and job events. The events can be recorded in chronological order as they happened or in summary form over a period of time by duration of event.

 

To the right is the screen for entering summarized availability data.

operator-web-availability.png
Operator Mobile Application

The Operator iOS and Android mobile applications allow a user to enter availability, performance, production, material change and job events. The events can be recorded in chronological order as they happened or in summary form over a period of time by duration of event.  A demonstration HTTP server is running a Collector at IP address 52.37.56.187 on port 8182 hosted on AWS Sightsail.

 

On Google Play Store, search for "Point85 Overall Equipment Effectiveness" or "OEE" application, use the direct URL.  An iOS mobile operator application is also released. On the Apple App Store, search for the "Point85 OEE Operator App" or "OEE" application.

operator-mobile-availability.png

For example, this is the screen for entering summarized availability.

This video shows the steps to set up the iOS mobile application.

Localization

All applications with user-visible text use resource bundles for localization. The locale is the default locale of the desktop or web server machine. Each application has two default resource bundles, one for text named (app name)Lang.properties and one for errors/exceptions named (app name)Error.properties with US English text as the default country code and language.

Database

The Java Persistence 2.2 API (JPA) as implemented by the Hibernate ORM framework together with the Hikari connection pool is used to persist OEE information to the database.

 

Hibernate and JPA abstract away database specific aspects of inserting, updating, reading and deleting records in the tables. The API is designed to work with any relational database supported by Hibernate.

Getting Started

The Java source code, binaries and documentation can be downloaded from these Github repositories:

 

The desktop applications are packaged in the oee-<version>.zip file in the latest Git release here. Download the oee-<version>.zip file and expand the archive into a folder of your choice. Next, download the Point85 OEE Getting Started Guide and follow instructions in that document. Additional information may be found in the Point85 OEE User Guide.

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