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I/Gear OEE Analysis &
root cause Tracking |
The Problem |
| I/Gear’s OEE Analysis & Root Cause Tracking solution improves a
manufacturer’s ability to meet delivery and production schedules. I/Gear’s
solution minimizes inefficiency by ensuring optimal use of assets and immediate
response to downtime delays. This is made possible with I/Gear’s
unique ability to integrate every machine asset in a manufacturing environment,
leading to accurate analysis of trends while notifying personnel as
problems occur. |
Manufacturers are often limited in their ability to determine when, how and
why a machine goes down or if a machine is performing to its potential.
Scrap is often manual in nature and rarely understood. Additionally, there is
a mixture of technologies on the plant floor that do not communicate with
each other or with IT and business systems. In summary, there are islands
of data on the plant floor and management personnel are in the dark with
respect to machine performance and improvement opportunities. |
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The Solution: |
| It is critical for manufacturers to look at their plant’s Overall
Equipment Effectiveness, or OEE, to understand machine
performance and return on investment. I/Gear’s OEE Analysis
and Root Cause Tracking solution establishes an automated
data collection interface to each asset on the plant floor,
while allowing operator input to provide a comprehensive assessment.
Data is collected, analyzed, and instantly driven to
communication systems, displays, and I/Gear’s Web interface.
The result is targeted action to resolve problems as they occur
and a greater understanding of improvement opportunities. |
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Features: |
- Automated machine interface for data collection
- Notification Services for immediate event notification via email, pager, radios, etc.
- Web reporting interface with dashboard
view, graphical view of current asset status
and historical production reports (good/bad
pieces, downtime events, throughput, cycle
time analysis and OEE factors)
- I/Gear TV for driving real time plant floor
data to plasma displays and plant floor
LED displays
- Operator entry of downtime and scrap
information via existing PLC HMIs, wireless
handhelds, thin clients
- Machine interlocking to force operator login
and downtime root cause entry
- Data transport of scrap and production
quantities to ERP systems
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I/Gear advantages: |
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Hardware independent (does not require
I/Gear data collection hardware) |
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Accessible from any networked computer |
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Expandable by customer to add assets
and reports |
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Expandable to include SPC charting,
traceability, error proofing and
other applications |
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Low upfront licensing and deployment
pricing model |
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System can be hosted on or offsite |
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Conducive to multiple plant deployments
and corporate rollup of plant data |
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Data Collection: |
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The solution is built on I/Gear DTU that seamlessly
interfaces with PLCs, displays, welders, torque guns,
databases, spreadsheets, ERP systems, email servers, ID
readers, vision systems and many other technologies. In
cases where an asset is not Ethernet capable, I/Gear’s
GearBox is used as an Ethernet data collection device. |
Report Filtering: |
| A report may be keyed off any system variable (i.e., asset,
product, operator, shift, production day, data range,
etc.). The I/Gear Web interface allows users to customize
data views and granularity. All data rolls up through
an asset tree structure, presenting common reports for
individual assets, lines, areas of the plant and the plant
as a whole. |
OEE Reporting: |
| I/Gear’s solution accommodates manual entry of
user-defined OEE variables such as shift schedule and
planned downtime. Users may define multiple takt
times per asset and may be manually or automatically
activated. |
Downtime Root Cause &
Scrap Entry: |
I/Gear’s solution allows operators to assign downtime
root causes and comments to automatically collected
downtime events. I/Gear’s solution also accommodates
manual entry of scrap data and will, in turn, adjust OEE
performance based on user assignment of scrap events.
Contact I/Gear today for more information or to
schedule a plant visit. |
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