How to Calculate Availability in JobBoss

Manufacturing availability is a crucial metric when calculating Overall Equipment Efficiency (OEE). It measures the amount of time that a manufacturing machine or process is available for production. By understanding and analyzing this metric, businesses can identify and address any issues that affect production efficiency. In this article, we will explore the value of availability when calculating OEE in JobBoss, key metrics for measuring availability, and a step-by-step guide to calculating manufacturing availability using JobBoss. We will also discuss how to utilize JobBoss features for accurate data and overcome common challenges in availability calculation. Additionally, we will explore the benefits of integrating smart factory tools to gain accurate availability insights.

Value of Availability Metric When Calculating OEE

Availability is one of the three key components of Overall Equipment Effectiveness (OEE), a widely used metric in the manufacturing industry to assess and improve operational efficiency. In addition to availability, OEE also takes into account performance and quality metrics to provide a comprehensive view of a production system’s effectiveness.

When calculating availability, businesses delve into the intricacies of machine uptime and downtime, shedding light on critical insights that drive operational decisions. By closely monitoring availability, companies can pinpoint recurring issues such as equipment breakdowns, maintenance delays, or setup changeovers that hamper continuous production flow.

Furthermore, the data derived from availability measurements serves as a roadmap for proactive maintenance strategies and process optimization initiatives. Through the lens of availability, organizations can proactively address underlying causes of downtime, implement predictive maintenance practices, and streamline production processes to enhance overall equipment reliability and performance.

Key Metrics for Measuring Availability in JobBoss

When measuring availability in JobBoss, there are several key metrics that businesses should consider:

1. Planned Downtime: This includes scheduled maintenance, changeovers, and other planned events that result in production stoppages. By tracking planned downtime, businesses can identify patterns and plan maintenance activities accordingly to minimize disruptions.
2. Unplanned Downtime: These are unexpected events that cause production stoppages, such as equipment breakdowns, power failures, or material shortages. Tracking unplanned downtime helps businesses assess the reliability of their equipment and identify opportunities for improvement.
3. Setup Time: Setup time refers to the time required to prepare the machine or process for production after a changeover or maintenance activity. By minimizing setup time, businesses can reduce production delays and increase overall availability.
4. Idle Time: Idle time occurs when a machine or process is available for production but remains unused due to factors such as waiting for materials, lack of orders, or inefficient production scheduling. Reducing idle time can significantly improve availability and overall production efficiency.

Additionally, another crucial metric for measuring availability in JobBoss is Mean Time Between Failures (MTBF). MTBF calculates the average time elapsed between one failure of a system and the next. This metric helps businesses predict the reliability of their equipment and plan maintenance schedules proactively to prevent unexpected downtime.

Overall Equipment Effectiveness (OEE) is a comprehensive metric that combines availability, performance, and quality to assess the overall productivity of a manufacturing process. By analyzing OEE, businesses can identify areas for improvement, such as reducing downtime, increasing production speed, and enhancing product quality, ultimately leading to higher efficiency and profitability.

Step-by-Step Guide to Calculating Availability in JobBoss

To calculate manufacturing availability in JobBoss, follow these step-by-step instructions:

Step 1: Access JobBoss ERP

1. Log in to JobBoss: Use your credentials to access the JobBoss system. Your user role and permissions will determine the modules and features available to you.
2. Navigate to the Shop Floor Control Module: This module is where you manage and monitor production activities, including the data required for calculating availability.

Step 2: Gather the Required Data

To calculate availability, you need two key data points:

1. Run Time: This is the total time that production equipment was actively running and producing goods.
   • Go to the Shop Floor Control or Job Tracking section within JobBoss.
   • Select the relevant job or work order.
   • The Run Time can be found in the Job Details or Shop Floor Activity records, where operators log their time spent on production tasks.
2. Planned Production Time: This is the total time that was scheduled for production, excluding planned downtime (e.g., scheduled maintenance or breaks).
   • In the same Job Details section, locate the planned production time.
   • This is typically set during job scheduling and can be found in the Work Order or Routing information, where planned times for each operation are recorded.

Step 3: Perform the Calculation

Once you have the necessary data:

1. Open a Calculator or Spreadsheet: JobBoss may not automatically calculate this specific availability metric, so you can perform the calculation manually or in a spreadsheet like Excel.
2. Calculate Availability:
   • Divide the Run Time by the Planned Production Time.

Step 4: Record and Analyze the Availability

1. Document the Calculation: Record the calculated availability percentage in a report, spreadsheet, or directly into JobBoss if your system allows for custom fields or dashboard integration.
2. Compare Against Targets: Evaluate the calculated availability against internal benchmarks or industry standards to assess the efficiency of your production processes.
3. Investigate Variances: If availability is lower than expected, use JobBoss’s analytics tools to investigate potential causes, such as unexpected machine downtime, delays in job start times, or other operational issues.

Step 5: Continuous Improvement

1. Monitor Availability Regularly: Continuously track availability data to identify trends, recurring issues, or opportunities for improvement.
2. Implement Process Improvements: Based on your analysis, take corrective actions such as optimizing work schedules, reducing unplanned downtime, or enhancing maintenance practices.
3. Leverage JobBoss Features: Utilize JobBoss’s features like Job Scheduling and Shop Floor Data Collection to automate data gathering, streamline calculations, and improve the accuracy of availability tracking.

Manufacturing availability is a critical metric for assessing the efficiency and productivity of a production facility. By calculating availability, manufacturers can gain insights into how effectively their resources are being utilized and identify opportunities for optimization. It provides a clear picture of the actual time that production equipment is operating and producing goods, allowing for targeted improvements to maximize output.

In addition to the steps outlined above, it is essential to consider factors that may impact manufacturing availability, such as preventive maintenance schedules, operator training, and equipment reliability. Regular maintenance checks and timely repairs can help minimize unplanned downtime, while investing in employee training can improve overall equipment effectiveness. By addressing these factors proactively, manufacturers can enhance their manufacturing availability and drive greater operational efficiency.

Utilizing JobBoss Features for Accurate Data

JobBoss, a comprehensive manufacturing management software, offers features that can help businesses accurately collect and analyze data for availability calculation:

• Machine Monitoring: JobBoss allows companies to integrate machine monitoring systems to capture real-time data on machine performance, downtime, and utilization. This data enables accurate availability calculation and timely decision-making.
• Maintenance Management: JobBoss provides tools to track and schedule maintenance activities, helping to reduce unplanned downtime and increase availability. By planning and executing regular maintenance, businesses can avoid equipment breakdowns and improve overall machine reliability.
• Production Scheduling: Efficient production scheduling in JobBoss minimizes idle time by ensuring machines are always utilized effectively. By optimizing production sequences and reducing changeover times, companies can enhance availability and productivity.

Furthermore, JobBoss offers a comprehensive reporting system that allows businesses to generate detailed reports on machine performance, maintenance activities, and production schedules. These reports provide valuable insights into areas for improvement and help in making informed decisions to optimize operations.

Another key feature of JobBoss is its integration capabilities with other software systems such as Enterprise Resource Planning (ERP) software. This integration streamlines data flow across different departments, ensuring seamless communication and data consistency. By connecting JobBoss with ERP systems, businesses can achieve a holistic view of their manufacturing processes and make data-driven decisions to improve efficiency and productivity.

Common Challenges in Availability Calculation

Calculating availability accurately can be challenging due to various factors. Some common challenges businesses may face include:

• Data Collection: Gathering accurate and comprehensive data on downtime, setup time, and idle time can be time-consuming and prone to human error. Implementing automated data collection systems helps overcome this challenge.
• Tracking Equipment Availability: Monitoring the availability of individual machines within a manufacturing facility can be complex, especially when there are multiple production lines or processes. Integrating machine monitoring systems simplifies this task and provides real-time visibility across the facility.
• Standardization: Ensuring consistent definitions and measurement methods for various downtime categories is important for accurate and meaningful availability calculation. Establishing standardized protocols and training employees on data collection and tracking is essential.

Another significant challenge in availability calculation is Accounting for Planned Downtime: While unplanned downtime is often easier to identify and quantify, planned downtime for maintenance, upgrades, or changeovers can be overlooked. Businesses need to have a clear process for documenting and factoring in planned downtime to ensure availability calculations are comprehensive and accurate.

Furthermore, Integration of External Factors: External factors such as supplier delays, transportation issues, or power outages can impact equipment availability. Incorporating these external influences into availability calculations requires a proactive approach to data collection and analysis. By considering these external factors, businesses can gain a more holistic view of their operational availability and make informed decisions to improve overall efficiency.

Integrating Smart Factory Tools for Accurate Availability Insights

Smart factory tools, such as Internet of Things (IoT) devices and advanced analytics software, can revolutionize the manufacturing industry by providing real-time data and predictive capabilities. These tools offer a plethora of benefits that can significantly enhance availability insights and streamline operations. By integrating smart factory tools with JobBoss, businesses can unlock a world of possibilities:

• Monitor Equipment Health: IoT devices play a crucial role in collecting data on various aspects of machine performance, including temperature, vibration, and other key parameters. This wealth of real-time information enables proactive maintenance strategies, helping to minimize unplanned downtime and extend the lifespan of equipment.
• Predict Maintenance Needs: The power of advanced analytics software lies in its ability to sift through vast amounts of historical data to identify patterns and trends. By leveraging this technology, businesses can predict maintenance needs with remarkable accuracy, allowing them to address issues before they escalate and disrupt operations. This proactive approach not only enhances availability but also leads to substantial cost savings in the long run.
• Optimize Production: Real-time data on machine status and availability empowers businesses to make data-driven decisions when it comes to production scheduling, changeovers, and resource allocation. By leveraging this information, companies can optimize their production processes, maximize equipment availability, and improve overall operational efficiency.

Furthermore, the integration of smart factory tools with JobBoss opens up avenues for continuous improvement and innovation within the manufacturing environment. By fostering a culture of data-driven decision-making and predictive maintenance, businesses can stay ahead of the curve and adapt to changing market demands with agility. The seamless synergy between technology and manufacturing processes not only enhances operational efficiency but also lays the foundation for sustainable growth and competitiveness in the digital age.

Schedule a Mingo Smart Factory Demo Today

Curious to see how many steps it takes to calculate availability in Mingo Smart Factory? The answer is one. The availability calculation is automatically done for you in the manufacturing dashboard. Overcoming common challenges in availability calculation and integrating smart factory tools further enhance availability measurement and provide proactive maintenance capabilities. By continuously monitoring and optimizing availability, companies can increase production efficiency, reduce downtime, and improve overall business performance.

Ready to take the next step in maximizing your manufacturing availability? Mingo Smart Factory offers a seamless, user-friendly solution that can be implemented swiftly, ensuring you won’t outgrow it. Our productivity platform is designed for operational teams to manage without the need for dedicated IT support. Whether you’re looking to connect to existing equipment or require hardware for data collection on older machines, Mingo has you covered. Don’t let another day of potential downtime impact your production. Talk to an Expert today and discover how Mingo Smart Factory can transform your manufacturing operations.