How to Calculate Availability in NetSuite

Manufacturing availability is a crucial metric for businesses looking to optimize their operations. It provides valuable insights into the efficiency and effectiveness of manufacturing processes. NetSuite, a leading cloud-based business management software, offers powerful tools for calculating manufacturing availability. In this article, we will explore the value of the availability metric, key metrics for measuring availability in NetSuite, and a step-by-step guide on how to calculate manufacturing availability using the platform. We will also discuss the importance of utilizing NetSuite reports for accurate availability data and address some common challenges in the calculation process. Additionally, we will delve into the benefits of integrating smart factory tools for more precise availability insights.

Value of Availability Metric When Calculating OEE

The availability metric plays a vital role in measuring Overall Equipment Effectiveness (OEE). OEE is a comprehensive measure that quantifies the efficiency of manufacturing equipment, taking into account availability, performance, and quality. Availability focuses specifically on the uptime of equipment, indicating the percentage of time that a machine or production line is available for production.

By calculating availability, businesses can identify bottlenecks, schedule preventive maintenance, and minimize downtime. This enables manufacturers to optimize productivity and meet production targets effectively. Moreover, availability data forms the foundation for evaluating machine reliability and scheduling necessary repairs or upgrades.

One key aspect of availability is understanding the different types of downtime that can impact production. Planned downtime, such as scheduled maintenance or changeovers, is essential for keeping equipment in optimal condition. Unplanned downtime, on the other hand, can result from unexpected breakdowns, material shortages, or other unforeseen issues. By tracking both planned and unplanned downtime, manufacturers can gain insights into the root causes of inefficiencies and take proactive steps to address them.

Furthermore, availability is closely linked to overall equipment reliability. High availability rates indicate that machines are operating consistently and as intended, contributing to a smoother production process. On the other hand, frequent breakdowns or prolonged downtime can significantly reduce availability and disrupt production schedules. By monitoring availability metrics over time, businesses can implement strategies to improve equipment reliability, such as investing in predictive maintenance technologies or enhancing operator training programs.

Key Metrics for Measuring Availability in NetSuite

NetSuite offers a range of key metrics for measuring availability effectively. These metrics enable businesses to gain valuable insights into the utilization of their manufacturing resources. By utilizing these metrics, companies can optimize their operations and improve overall efficiency.

One crucial metric for measuring availability in NetSuite is Overall Equipment Effectiveness (OEE). OEE combines various factors, including availability, performance, and quality, providing a holistic view of equipment effectiveness. By analyzing OEE data, businesses can identify areas for improvement and implement strategies to enhance productivity.

• Overall Equipment Effectiveness (OEE): As mentioned earlier, OEE combines various factors, including availability, performance, and quality, providing a holistic view of equipment effectiveness.
• Machine Uptime: This metric quantifies the percentage of time a machine or production line operates without experiencing any failures, breakdowns, or unplanned downtime.
• Planned Downtime: Planned downtime includes scheduled maintenance, changeovers, and other planned activities that result in the temporary unavailability of equipment.
• Unplanned Downtime: Unplanned downtime refers to unexpected equipment failures or breakdowns that cause delays in production.

Another essential metric to consider is Mean Time Between Failures (MTBF). MTBF calculates the average time elapsed between equipment failures. By monitoring MTBF, organizations can predict maintenance schedules, reduce downtime, and enhance operational efficiency. Implementing preventive maintenance strategies based on MTBF data can significantly improve equipment reliability and availability.

Step-by-Step Guide to Calculating Availability in NetSuite

Calculating manufacturing availability in NetSuite involves several steps. Here is a step-by-step guide to help you navigate the process:

Step 1: Access NetSuite ERP

1. Log in to NetSuite: Use your credentials to access the NetSuite system. Your access level will determine which modules and features you can use.
2. Navigate to the Manufacturing Module: This module contains the tools and data necessary for managing and monitoring production activities, where you’ll find the information 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.
   • Navigate to the Manufacturing or Work Orders section within NetSuite.
   • Select the relevant work order or job.
   • The Run Time can be found in the Work Order Completion or Production Tracking records, where operators log their time spent on production tasks.
2. Planned Production Time: This is the total time scheduled for production, excluding planned downtime (e.g., scheduled maintenance or breaks).
   • In the same Work Orders section, locate the planned production time.
   • This is typically set during the job scheduling process and can be found in the Work Order Details or Routing records, 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: NetSuite 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 NetSuite 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 NetSuite’s analytics and reporting tools to investigate potential causes, such as unexpected downtime, delays in job start times, or other operational inefficiencies.

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 improving equipment maintenance practices.
3. Leverage NetSuite Features: Utilize NetSuite’s advanced features like Work Order Scheduling, Production Management, and Analytics to automate data collection, streamline calculations, and enhance the accuracy of availability tracking.

Manufacturing availability is a critical metric that directly impacts production efficiency and overall profitability. By accurately calculating availability, businesses can pinpoint areas of inefficiency and implement targeted solutions to optimize their manufacturing processes.

Furthermore, monitoring manufacturing availability in NetSuite provides real-time insights into the health of production operations. This data allows managers to make informed decisions regarding resource allocation, maintenance schedules, and production planning, ultimately leading to increased productivity and cost savings.

Utilizing NetSuite Reports for Accurate Availability Data

NetSuite offers robust reporting capabilities that can enhance the accuracy of availability data. By utilizing customizable reports, manufacturers can generate real-time insights into equipment availability, planned and unplanned downtime, and other related metrics. These reports enable businesses to monitor performance, identify trends, and make informed decisions regarding resource allocation, maintenance schedules, and process improvements. NetSuite’s reporting functionality, combined with accurate availability data, empowers manufacturers to continually optimize their operations and drive productivity.

Moreover, NetSuite’s reporting features extend beyond just equipment availability data. Users can also leverage the platform to track inventory levels, analyze sales performance, and forecast demand. This comprehensive suite of reporting tools provides manufacturers with a holistic view of their operations, allowing them to streamline processes, reduce costs, and improve overall efficiency. By harnessing the power of NetSuite reports, businesses can gain a competitive edge in today’s fast-paced market environment.

Furthermore, NetSuite’s reporting capabilities are not limited to internal operations. Manufacturers can also use the platform to create custom reports for external stakeholders, such as suppliers, partners, and customers. These reports can be tailored to showcase key performance indicators, supply chain metrics, and production forecasts, fostering transparency and collaboration across the entire value chain. By sharing relevant data through NetSuite reports, manufacturers can strengthen relationships, improve communication, and drive mutual success in the industry.

Common Challenges in Calculating Availability

While calculating manufacturing availability, organizations may encounter various challenges that can impact the accuracy of the results. Some common challenges include:

• Lack of data visibility: Incomplete or outdated data can hinder the calculation process and lead to inaccurate availability metrics.
• Inconsistent data collection: Inconsistent data collection practices across different departments or locations can introduce discrepancies in availability calculations.
• Human error: Manual data entry or reliance on spreadsheets increases the risk of human error, potentially affecting availability calculations.
• Complex production environments: Manufacturing processes involving multiple machines, production lines, or facilities can make availability calculations more complex and challenging.

Recognizing these challenges is essential to implement strategies that mitigate their impact on availability calculations. Automation, standardized data collection protocols, and leveraging advanced manufacturing software can help overcome these hurdles and ensure accurate availability metrics.

Another significant challenge in calculating manufacturing availability is the integration of legacy systems with modern technology. Many manufacturing facilities still rely on outdated systems that may not seamlessly integrate with newer software solutions designed for availability calculations. This integration gap can result in data silos, where crucial information is scattered across different platforms, making it difficult to obtain a comprehensive view of availability metrics.

Moreover, external factors such as supply chain disruptions, unexpected machine breakdowns, or changes in production schedules can further complicate availability calculations. These unforeseen events can impact production capacity and downtime, influencing the overall availability of manufacturing processes. It is crucial for organizations to have contingency plans in place to address these external factors and minimize their effects on availability calculations.

Integrating Smart Factory Tools for Accurate Availability Insights

To further enhance availability insights, businesses can integrate smart factory tools with NetSuite. Smart factory tools leverage technologies such as IoT devices, sensors, and advanced analytics to provide real-time data on equipment performance, maintenance needs, and availability. By connecting these tools to NetSuite, manufacturers can seamlessly collect and analyze data, gaining deeper visibility into availability metrics. This integration allows for proactive maintenance, real-time alerts on machine issues, and data-driven decision-making to optimize availability. Implementing smart factory tools alongside NetSuite empowers organizations to stay ahead in today’s fast-paced, data-driven manufacturing landscape.

One of the key benefits of integrating smart factory tools with NetSuite is the ability to create predictive maintenance schedules based on real-time equipment data. By analyzing historical performance trends and current machine conditions, manufacturers can anticipate maintenance needs and schedule downtime during off-peak hours, minimizing production disruptions. This proactive approach not only extends the lifespan of equipment but also reduces maintenance costs and improves overall operational efficiency.

Furthermore, the integration of smart factory tools with NetSuite enables manufacturers to implement condition-based monitoring strategies. By setting up thresholds for key performance indicators and receiving automated alerts when values deviate from the norm, organizations can address potential issues before they escalate into costly breakdowns. This real-time monitoring capability not only ensures continuous production flow but also enhances product quality by preventing defects and minimizing rework.

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.  Integrating smart factory tools takes availability insights to the next level, offering real-time visibility and enabling proactive maintenance. With the power of NetSuite and the right approach, businesses can successfully calculate manufacturing availability and unlock the potential for optimized operations.

Ready to take your manufacturing availability to new heights? Mingo Smart Factory offers the ultimate solution that’s quick to implement and easy to manage, ensuring you never outgrow your manufacturing system. With our plug-and-play productivity platform, you can deploy in days, not months, and customize it to meet your unique operational needs without the need for dedicated IT support. Connect Mingo directly to your equipment, or let us provide the necessary hardware for seamless data collection on older machines. Don’t miss the opportunity to transform your operations. Talk to an Expert today and unlock the full potential of your manufacturing processes.