Oee on hana overall equipment effectiveness overview aug 2012 (2)

OEE on HANA
Overview of the Solution Capability and Architecture
SAP Manufacturing Performance Management
August 2012

© 2011 SAP AG. All rights reserved. 2
What is OEE?
OEE (Overall Equipment Effectiveness) can be described as a universally
accepted set of metrics that bring clear focus to the key success drivers for
manufacturing enterprises.
OEE is the measurement technique that has been in practiced for many years,
albeit with a narrower purpose. Historically, OEE was used as a top level summary
view of capacity and its utilization. In recent years it has reappeared but with a more
valuable multi-level view of the business, placing emphasis on the underlying issues
that limit performance. The resurgence of OEE is doubtless related to its ability to
plainly portray the opportunities for improvement that exist for all manufacturers.
Functionally, these metrics provide the basis by which excellent manufacturers
can systematically direct their business towards attainment of critical objectives like:
Improving Operating Margins
Optimized Competitive Position
Maximized Utilization of Capital
Internal and Confidential

OEE on HANA
Overview
Value Added for Customer
Global planning with real time visibility to distributed plant level execution
Reduced manufacturing cost through waste reduction
Maximize return on capital investment by improving utilization
Increased customer satisfaction by constant monitoring on Speed of production and
Quality
A tool which drives continuous improvement of manufacturing performance
CUSTOMERVALUESHORTDESCRIPTION
Context/Use Case
OEE is a Plant Performance Management Solution with:
Universally accepted set of metrics
Clear focus to the key success drivers for manufacturing enterprises
Emphasis on the underlying issues that limit performance
A “Comprehensive Loss Analysis” tool for the manufacturing shop floor
Real time, scalable and extensible solution
Operator grade User interface for shop floor execution

Overall Equipment Efficiency (OEE) on HANA
Leverage immediately the power of In-Memory for analytics for OEE
HANA provides the best environment for OEE from a technical perspective:
A combination of data aggregation mechanisms with business logic & algorithms. It allows flexible drill
down capabilities from the top aggregated level down to the individual record.
No intermediate step on classical DB, no future migration for customers
With HANA customers can easily build additional manufacturing analytics on top of OEE
Provide one tool & user experience for both enterprise and plant reporting based on up-to-date
technologies
HANA will be the basis for future real time and predictive operational intelligence
OEE is the first step towards an In-Memory Manufacturing Performance Management solution
Real time and predictive Analytics will be further steps leveraging the power of HANA to allow improved
process yield, resource consumption, product and process quality through real-time monitoring of
production performance
Build OEE directly on In-Memory is the first step towards a new era of
Manufacturing Analytics and Operational Intelligence
KEY MESSAGE

OEE Key Stakeholders & Objectives
Ensure effective
manufacturing execution
Ensure smooth
production run
Define/Implement
successful Operation
Strategy
How do I meet all
requirements and
maximize productivity ?
How do I gain visibility to
the status of
manufacturing
performance across
plants ?
How do I manage
manufacturing
operations efficiently and
avoid negative impact to
the plant image?
How do I execute my
daily tasks efficiently ?
Reduce operating
costs
Increase true
capacity/decrease
time to produce
Increase return on
assets
Better manage and
allocate capital
How do I ensure safe
operations through cost
effective maintenance
and reliability programs?
Ensure daily targets are
maintained
OEE Metrics
Production performance
Maintenance performance
Capacity Utilization
Asset Utilization
Mfg Costs
Production and Shift
performance
Output against Targets
Shop floor losses
Throughput, Utilization
Maintenance Performance
Downtime Analysis
Machine Breakdowns
Ratio Planned / Unplanned
Maintenance
Meantime between failures
Work Performance
Setup times
Throughput
Shop floor losses
COO
Maintenance /
Engineering Manager
KPI´s:
Business Needs:
VP Operations Plant Manager / Plant
Supervisor Operator

Customer Challenges
Absence of a standardized scalable tool across manufacturing
facilities to measure and compare performance
Challenges in finding hidden areas for possible improvements on a
continuous basis which limits performance
A near-real time analytics to analyze shop floor data
Driving Business Transformation on the shop floor
Key Product Features
Deliver analytical capabilities against plant and other business data
Leverage existing ERP master data already available with almost
no duplicate configuration
Close the loop via monitoring and alerts
Global plan to get executed in large distributed factories
Enables measurement of plant performance resembling the plant
actual hierarchy
Enables collection of plant data analyzed across customer defined
multi-level loss trees in real time – Manual and automatic data
collection
State-of-the-art operator grade User Interfaces for real time data
collection
Role:
Plant Manager, Operator, Line
Supervisor, VP Operations,
Manufacturing Heads
Target
Segment
Installed base and net new
customers in the Manufacturing
Industries
Scrum
team
1 Scrum team
7 developers, 1 PO, 1 Architect
Planned
RTC
27 May 2013
UI Type HTML5
Integration SAP MII
Analytics SAP HANA
OEE on HANA
Customer Challenges and Product Features

Overall Equipment Effectiveness
Time Elements of OEE
Efficiency Loss
(ELrep)
Speed Loss(SL)
Quality Loss (QL)
In-line
Rejections
Off-line
Rejections
NET OPERATING TIME / TARGET HOURS
(NT) or (TH)
Fully Productive Time /
VALUE OPERATING TIME
(VT)
Performance
Loss
(PL)
PLANT OPERATING TIME / TOTAL TIME
(TT )
PLANNED PRODUCTIVE TIME / LOADING TIME /GROSS PRODUCTION HOURS
(LT) or (GPH)
Shutdown Losses /
Planned Downtime (SD)
Idle Time (IT)
EQUIPMENT PRODUCTIVE TIME /
OPERATING TIME / NET PRODUCING HOURS
(PT) or (NPH)
Downtime losses /
Unplanned Downtime
(UD) or (DH)
* Definition of the time elements are flexible
* Reason code definitions are multilevel

Addressing the “Major Losses” of Production
Reducing planned downtime
due to meetings, breaks,
material shortages,
maintenance (Utilization)
Eliminating breakdowns and
unplanned downtime through
root cause analysis
(Availability)
Tracking and reducing changeover, set up time and
adjustments (Availability)
Reducing minor stops for misfeeds, blocks, jams that
do not require maintenance (Performance)
Reducing speed loss and anything that prevents
running at maximum speed (Performance)
Reducing scrap and rework due to start up (Quality)
Reducing scrap and rework during steady state production (Quality)
EfficiencyLoss
(ELrep)
SpeedLoss(SL)
Quality Loss (QL)
In-line
Rejections
Off-line
Rejections
NET OPERATING TIME / TARGET HOURS
(NT) or (TH)
Fully Productive Time /
VALUE OPERATING TIME
(VT)
Performance
Loss
(PL)
PLANT OPERATING TIME / TOTAL TIME
(TT )
PLANNED PRODUCTIVE TIME / LOADING TIME /GROSS PRODUCTION HOURS
(LT) or (GPH)
ShutdownLosses /
PlannedDowntime (SD)
Idle Time (IT)
EQUIPMENT PRODUCTIVE TIME /
OPERATING TIME / NET PRODUCING HOURS
(PT) or (NPH)
Downtime losses/
UnplannedDowntime
(UD) or(DH)

Standard OEE Calculations
OEE = Availability x Performance x QualityOEE = Availability x Performance x QualityOEE = Availability x Performance x QualityOEE = Availability x Performance x Quality
IT – Idle Time
SD – Scheduled Down
UD – Unscheduled Down
DH – Downtime Hours
SL – Speed Loss
PL – Performance Loss (calculated)
ELrep – Efficiency Loss(reported)
EL = 0
Standard calculations can be configured and extended

OEE Operator UI
Contact information:
F name MI. L name
Title
Address
Phone number

Operator UI for Event Capture
Ability to view real time status and change status of equipment
Real time red, yellow, green light status of all machines on a line
Ability to change the current status of any machine (up and down)
Ability to record speed loss and short stops
Multi-tiered reason code structure and comments for root cause and corrective action
Ability to indicate start and stop of production
Record the starting and stopping of production with associated PO number, material,
operation, recipe, etc.
Ability to easily switch between PO’s as production changes
Ability to record production
Record quantities of good and bad product made and reasons (acceptable vs.
avoidable loss)
Configurable “bad product categories for scrap, rework, waste, rejects, etc.
Production recorded in both real-time and batch modes

Operator UI for Monitoring Production
Ability to view real time OEE event activity and KPI’s
Near real time calculations for OEE, Availability, Quality, Performance, up and down
time, actual vs. nominal speed, production quantity vs. plan, etc.
List of all OEE events for all machines the line in chronological order
Ability to maintain event information (i.e., specify reason codes and comments)
Automated interface to ERP and shop floor systems used to collect shop floor
event information used for OEE calculations
PP and PP/PI interface for production orders
PM interface for maintenance work orders
Configurable, standardized interface mechanism for all other plant systems for real-time
collection of all OEE event types
Alerting
Real time alerting for KPI’s out of target with configurable recipients and delivery time
frames
UI pop-up, SMS, email, system generated messages, web services, etc.

Operator Dashboard
Real time calculations for the current Order
Real time OEE calculations happens in HANA
Custom / Extensible
Operator Menu
Collapsible SAP
provided Operator
Menu
Possible Integration
with MII 14.0 Alert
Framework
Line Status
Machine Status

Extension possibilities of the Operator dashboard
Right side menu is collapsible and provided by the SAP
standard solution, where as the bottom part is for custom
extensions
Custom Extensible Menu for specific activities can be used in
different ways, e.g.:
Manual additional data collection
Showing additional data from the shop floor, e.g.:
Safety Instructions / Control Recipies
Node specific configuration will give option to define button
profiles and follow up link
On click the pop-up will show up as modal window
OEE solution will provide templates / interfaces / Queries to
facilitate the access of the current order information and
posting additional data to the HANA box

Raising Alert – Possible Integration with MII 14.0 Alert Framework
Alert can be raised from shop floor by
integrating with MII 14.0 Alert Framework
feature
Role specific mail notifications can be
configured in the Alert Framework
Displays of list of Alerts for relevant
user roles is also achievable through
Alert Framework integration

OEE Dashboards and
Analytics
F name MI. L name
Title
Address
Phone number

OEE Dashboard and Analysis Examples
Summary Dashboards and Reporting
OEE, Availability, Performance, Quality
Shift Performance
Availability
Actual vs. target overall availability over time
Planned vs. actual productive time (asset utilization) compared to target
Pareto of downtime loss (time) and frequency (number of occurrences) by reason
Pareto of Mean Time Between Failure, Mean Time to Repair, Failure Rate, Failure
Frequency Rate
Performance
Actual vs. target overall performance over time
Actual vs. nominal speed and performance compared to plan or target
Speed loss affect on planned production quantity and pareto of reasons. How much
product is being lost as a result?
Quality
Actual vs. target overall quality over time
Good vs. bad product comparison and pareto of reason codes

OEE Analysis Capability
Dashboard views for all OEE KPI’s and associated analysis
Library of pre-defined UI objects for configurable dashboards and reporting by user,
user group, role, etc.
Drill down from one KPI to any related or children KPI’s
Dimensions of OEE analysis
Dill down and across on Hierarchy – business unit, plant, area, line, work center,
equipment
Drill down on time – hourly, shift, day, week, month, quarter, year
Filter by shift and material
Comparison views to compare KPI on dimensions of hierarchy, time, material, shift
Alert and Exception Driven
Real time exception driven alerts by user role and delivery mechanism
Actual vs. target for all KPI’s and highlighted exceptions of missed target, goal,
threshold
Drill down on exception
Ad-hoc reporting for root cause analysis
Configuration
Pre-defined UI content objects for configuration and extension of customized
dashboards and reports

Loading
time/Gross
Production
Hours
Down
time/Idle
Hours +
Down Hours
Production
time/Net
Production
hours
Net operating
time/ target
hours
Speed loss
+ Efficience
loss
Downtime
losses
Speed
Losses
Quality
Losses
Time dimension
Reporting hierarchy
Materials
Reason codes
Machine Groups
Material Groups
?XXX? XX
X X? X X X ?
X X x ?
XXXX
X X X X
X
XX X X X X X X
X XX X X X X X
Time related Financial Loss related
KPI
Dimension
Analytics – KPIs and Dimensions
Sample : Subjected to changesMTBF ? - Clarifications required
MTTR ? – Clarifications required
Perfect Order Deviation - under discussion
Maintenance Schedule Adherence - under discussion
Raw material consumption / Utility consumptions - under discussion

Analytics – KPIs and Dimensions
Produced
quantities
Rejected
quantities
Accepted
quantities Availability Performance Quality OEE
Time dimension
Reporting hierarchy
Materials
Reason codes
Machine Groups
Material Groups
?XXX
X X
XX
X X X ?
? X
X X
X
X X X X X
X X XX X X X
Quantities related OEE related
KPI
Dimension
Sample : Subjected to changes

HANA Based Report Analysis
HANA Modeling
( Calculation Views )
UI5 Based
Reports
HANA UI Clients
(BOBJ, Analysis
Office etc.)
Other Reporting
Tools (MS Excel
etc.)

HANA Modeling and Analysis
HANA calculation views would be created for different reports to be consumed from UI
clients
For basic KPIs like Total Production Time, Scheduled Downtime, Availability,
Performance, Quality etc. predefined calculation views will be delivered.
Customers can create any calculation views for any newly defined KPIs and reports.
UI5 based reports/charts will be provided for basic reports analysis.
HANA reports can also be consumed by SAP standard UI tools like BOBJ, Analysis
Office, visual Intelligence etc. These tools can be easily used by business users without
much complexity.
Its also possible to use third party UI tools like MS excel.

2011-12-
01
2011-12-
02
2011-12-
04
2011-12-
06
2011-12-
07
2011-12-
08
2011-12-
09
2011-12-
10
2011-12-
11
2011-12-
12
1200
004
PACKING_STATION 6 1086 1650 490 10
H_BLENDER 5 8 3 604 895 492 1094 937 70
B_FILLER 4 8 604 297 1278 751 757 131
0
500
1000
1500
2000
2500
3000
3500
4000
Durationinseconds
ReasonCode (Blockage) Daily Trend
Duration reported on 3 nodes in hierarchy for Blockage Reason code.
Aggregation is daily from 1 December 2011 to 12 December 2011.
Analytics – Sample Charts - Trends

Analytics – Sample Charts - Comparisons
Duration reported on all nodes in hierarchy for 2 states: Mechanical and Electrical Breakdown.
Aggregation is monthly for month of December.

OEE Configuration
F name MI. L name
Title
Address
Phone number

OEE on HANA
Implementation Setup
Internal and Confidential

Configuration Items and Activities
Define Time and Data Collection elements
Define Machine Groups, Production Modes, KPIs, Reason Codes
Define the Hierarchy Template
Define Machines
Define the Hierarchy – Maintain Bottlenecks, Nominal Rate, KPI Targets
Publish the Hierarchy
Excel based data creation utility – Plant hierarchy and Reason code
Integration module : ERP and MII
Configure the Operator UI and Activities

Architecture
F name MI. L name
Title
Address
Phone number

Overall Equipment Efficiency on HANA
Architecture Overview
Central repository
enables global
visibilitywith full
drill-down
Use of raw data
instead of complex
aggregation and
synch mechanisms
Real-time execution
of complex KPI
calculation
algorithms
Direct machine
connectivityto
collect status
informationetc
Data buffering at
plant level through
MII/PCo

Shop Floor
HANA Box
PCo
MII
Notification
Trigger Transaction
Post Event
Data to HANA
system
Data collection is possible through manual and automatic
interfaces
Both manual and automatic will have defined set of interfaces
provided by the SAP OEE solution
Example:
Automatic:
ReportStatusChane (WorkUnitID, TargetState, OccuranceTime,
ReasonCode, ProducitonMode, MarkParentDown )
Manual:
ReportStatus ( WorkUnitID, TargetState, StartTime, EndTime,
ReasonCode, MarkParentDown )
Data collection Interfaces

HANA Box
Plant - 1
PCo
Data collection Interfaces
Plant - 2
PCo
… …
MII
MII MII
… …
ECC
Plant - n
PCo
MII can post event data to HANA
real time and can also buffer when
required
Sample Manual Interfaces
ReportStatus, GetStatusHistory,
MaintainStatusHistory,
ReportOperationStart,
ReportOperationStop,
GetConfirmations,
MaintainConfirmations
Sample Automatic Interfaces
ReportStatusChange,
ReportOperationStart,
ReportOperationStop,
GetConfirmations
Maintenance of event data
mandatorily required the HANA
system to be connected

Solution Architecture

Thank You!
F name MI. L name
Title
Address
Phone number

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