Graphical overall equipment effectiveness system & method

• US 20040117050A1
• Filed: 10/14/2003
• Published: 06/17/2004
• Est. Priority Date: 10/15/2002
• Status: Abandoned Application

• Current Assignee: Factoryware Incorporated
• Original Assignee: Factoryware Incorporated
• Inventors: Boctor, David T., Oskin, John
• Application Number:
  US10/685,084
• Publication Number:
  US 20040117050A1
• Time in Patent Office: Days
• US Class Current: 700/108
• CPC Class Codes: G05B 2219/31411 Down time, loss time estimation, calculation
• CPC Class Codes: G05B 23/0267 Fault communication, e.g. human machine interface [HMI]

Abstract

A method, computer readable medium or modulated signal, and system for monitoring the operational efficiency of equipment. Performance and scheduling data is used to calculate an overall equipment effectiveness, performance loss value, and quality loss value. These values are displayed in a graphical format display, such as in a pie chart, to visually indicate what percentage of a maximum planned product time is actually devoted to producing product. The graphical format display shows the productivity diminishing factors in a simple format to allow both operators and management to quickly analyze production. The system may include multiple sensors and multiple terminals for retrieving data and graphically displaying overall equipment effectiveness information.

Claims

1. A method for monitoring operational efficiency of equipment in a, the method comprising the steps of:

calculating an availability value;

calculating a performance value;

calculating a quality erosion value;

defining an overall equipment effectiveness value as the product of the availability value, the performance value, and the quality erosion value;

calculating a performance loss value;

calculating a quality loss value;

displaying the overall equipment effectiveness value, the performance loss value, and the quality loss value in a graphical format display.

2. The method of claim 1, further comprising the step of converting the overall equipment effectiveness value, the performance loss value, and the quality loss value to a percentage of a maximum planned production time prior to being displayed in a graphical format display.

3. The method of claim 2, further comprising the step of displaying the graphical format display as a pie chart having a plurality of wedges, the plurality of wedges including at least a wedge corresponding to the overall equipment effectiveness value, a wedge corresponding to the performance loss value, and a wedge corresponding to the quality loss value, wherein each wedge in the plurality of wedges has a dimension proportional to the wedge'"'"'s corresponding value.

4. The method of claim 3, further comprising the step of displaying the plurality of wedges further comprises performance diminishing values expressed as a percentage of a maximum planned production time.

5. The method of claim 4, further comprising the step of having the performance diminishing values be a break value, a setup value, a shift transition value, and a minor downtime value.

6. The method of claim 2, further comprising the step of improving operational efficiency by examining the graphical format display and adjusting scheduling to reduce values that diminish the overall equipment effectiveness value.

7. The method of claim 2, further comprising the step of improving operational efficiency by having an operator view the graphical format display and having the operator take corrective action to improve the overall equipment effectiveness value.

8. The method of claim 7, further comprising the step of having the corrective action be reducing the duration of a break.

9. The method of claim 7, further comprising the step of having the corrective action be reducing equipment setup time.

10. The method of claim 7, further comprising the step of having the corrective action be reducing delays due to shift transitions.

11. The method of claim 7, further comprising the step of rewarding an operator who improves the overall equipment effectiveness value.

12. The method of claim 7, wherein an output device for displaying the graphical format display is positioned alongside the operator.

13. A computer-readable medium or modulated signal being encoded with computer-readable instructions to perform a method of monitoring operational efficiency comprising:

calculating an availability value;

calculating a performance value;

calculating a quality erosion value;

defining an overall equipment effectiveness value as the product of the availability value, the performance value, and the quality erosion;

calculating a performance loss value;

calculating a quality loss value;

displaying the overall equipment effectiveness value, the performance loss value, the quality loss value, in a graphical format display.

14. A system for monitoring operational efficiency of equipment, the system comprising:

a module that;

calculates an availability value;

calculates a performance value;

calculates a quality erosion value;

defines an overall equipment effectiveness value as the product of the availability value, the performance value, and the quality erosion value;

calculates a performance loss value;

calculates a quality loss value;

displays the overall equipment effectiveness value, the performance loss value, the quality loss value, in a graphical format display.

15. A system for monitoring the operational efficiency of a plurality of equipment, the system comprising:

a module that calculates an availability value, calculates a performance value, calculates a quality erosion value, defines an overall equipment effectiveness value as the product of the availability value, the performance value, and the quality erosion value, calculates a performance loss value, and calculates a quality loss value; and

a plurality of terminals in networked communication with the module, each of the plurality of terminals being positioned at an operator location for each of the plurality of equipment, each terminal having an output device for displaying at least the overall equipment effectiveness value, the performance loss value, and the quality loss value in a graphical format display.

16. The system for the monitoring the operational efficiency of equipment, the system comprising:

a sensor in reporting communication with the equipment for monitoring at least the up-time and down-time for the equipment; and

a module in electrical communication with the sensor and receiving data from the sensor, the module operative to;

use the data to calculate an availability value;

use the data to calculate a performance value;

use the data to calculate a quality erosion value;

define an overall equipment effectiveness value as the product of the availability value, the performance value, and the quality erosion value;

calculate a performance loss value;

calculate a quality loss value; and

display the overall equipment effectiveness value, the performance loss value, and the quality loss value in a graphical format display.

17. The system of claim 16 further comprising at least one additional sensor in reporting communication with at least one additional equipment, each additional sensor in communication with the module.

18. The system of claim 16 further comprising a terminal in networked communication with the module, the terminal being positioned at an operator location for the equipment, the terminal having an output device for showing the graphical format display.

19. The system of claim 18 further comprising at least one additional terminal in networked communication with the module and at least one additional equipment, each additional terminal being positioned at an operator location for each additional equipment.

20. The system of claim 16, wherein the sensor also monitors historical product-related values.