ProAlert
Performance analytics calculations
This page documents the arithmetic behind performance analytics, discipline 8 of the fourteen ProAlert covers. OEE (Overall Equipment Effectiveness) is one output of that module, not the product. The definitions matter because two plants reporting different numbers are often performing identically and simply counting planned time differently. These are the definitions ProAlert uses.
Core calculations
- Planned Operational
- Time frame - Total Planned DT
- Run Time (Operational Time)
- Planned Operational - Total DT
- Target Cycles
- Run Time * (Work Center/Product defined rate for cycles/hour)
- Actual Units
- Actual Cycles * (Work Center/Product defined ratio Units/Cycle)
- Availability
- Run Time / Planned Operational
- Performance
- Actual Cycles / Target Cycles
- Quality
- (Actual Units - (scrap: mfg + other + rework)) / Actual Units
- OEE
- Performance * Availability * Quality
- Mean Time to Failure (MTTF)
- Operational Time / Number of DT Events (Minutes)
- Mean Time to Recovery (MTTR)
- Total DT / Number of DT Events (Minutes)
ProAlert's relevant business rules
- Only one Planned DT can exist per work center at one time
- Multiple DT events can exist at one time for a work center
- ProAlert will condense multiple WC DTs into one value where calls overlap
- Planned DTs will reduce DT times by the amount they overlap, mitigating the negative effects of DTs
ProAlert OEE calculation differences
- Run Time (Operational Time)
- Planned Operation - reduced Total DT (where planned overlapped unplanned)
Additional calculations
- Salvaged Time (overlap of planned/unplanned)
- Start/Stop time variances compared to schedule
- Time to First Cycle after down times
Seeing it work
The OEE Sandbox on the product site applies these rules to a simulated shift so you can watch the numbers move as runs, downtime calls and scrap events are added.
Where the score goes next is the point of running analytics inside a platform. A low availability figure resolves to specific downtime calls, which resolve to work orders, parts and a failure classification, all in the same database. See the platform overview.