Increasing the Value of OEE with Manufacturing Asset Performance Management (APM) 

Traditional Overall Equipment Effectiveness (OEE) provides historical data on equipment performance, measuring factors such as availability, performance, and quality. While useful, OEE primarily offers a retrospective view of manufacturing operations. Alternatively, Manufacturing Asset Performance Management (APM) enhances OEE by providing real-time dashboards and insights, building on historical data with current operational visibility.

Advances in industrial automation technology have transformed manufacturing asset management, enabling data to be presented with greater context and actionable insights in order to meet high priority goals, such as cycle time reduction and throughput improvement.

The Challenge of Relying on OEE Alone

OEE primarily provides historical data on equipment performance, focusing on availability, performance, and quality metrics without real-time visibility. This retrospective approach can delay the identification of issues, leading to extended downtime and inefficiencies that could possibly have been avoided given access to real-time plant floor data.

Additionally, OEE often requires manual data entry and analysis, which can introduce errors and inconsistencies. It also lacks the contextual insights, such as fault code analysis, operator interaction data, and process flow data, just to name a few, needed to fully understand root causes of performance losses. Lacking these insights makes it difficult for manufacturers to make proactive, data-driven decisions for ongoing process improvement.

What is APM in Manufacturing

Manufacturing asset management involves a standardized AOI (Add-On Instructions) for PLC code, capturing essential process data for various applications aimed at enhancing operational efficiency. It facilitates the transfer of information between PLCs on the plant floor and the SCADA platform, automatically pulling all necessary information for OEE analysis, tracking total bad parts, fault code reasons, and more, and visual displaying the data via Andon boards.

Key Features of Asset Performance Management Software

1. Factory Information System (FIS):
   • Serves as the core analysis engine to assess past performance.
   • Built using Ignition, offering complete customization by the client.
   • Andon dashboards display equipment states, OEE information, and production data.
2. Automated Data Collection and Analysis:
   • Continuously collects data from PLCs and sensors across the production line.
   • Automates data aggregation and analysis, reducing manual data entry and human error.
3. Cycle Time Analysis (Constraint Analysis):
   • Identifies bottlenecks by analyzing cycle times and constraints.
   • Andon dashboards help pinpoint where issues occur and identify root causes.
   • Built on OEE metrics, this feature helps address productivity limitations.
4. Modes and States Dashboard:
   • Provides real-time visibility into current operations.
   • Displays equipment status and other critical operational data.
5. Root Cause Analysis (RCA):
   • Provides tools to investigate the root cause of recurring faults or inefficiencies.
   • Uses historical data trends and fault code tracking for in-depth problem-solving.
6. Downtime and Loss Tracking:
   • Monitors downtime reasons and categorizes production losses.
   • Helps identify patterns leading to unplanned stops or reduced performance.

Integration with SCADA and MES

When complemented by Manufacturing Asset Performance Management, OEE metrics gain significant power by transforming historical performance data into real-time, actionable insights. APM extends OEE’s capabilities by offering deeper context and visibility into equipment performance, fault diagnostics, and process conditions.

By integrating APM with SCADA and MES (Manufacturing Execution Systems), manufacturers can create a comprehensive, unified operational view where critical data flows seamlessly across platforms. This enhanced connectivity not only improves plant-wide visibility but also empowers more informed decision-making, proactive maintenance, and optimized production control.

Gain a Competitive Edge with APM in Manufacturing