Calculating manufacturing availability is crucial for evaluating the efficiency of production processes in Plex. This metric provides valuable insights into the downtime and operational reliability of equipment, helping manufacturers identify areas for improvement and optimize overall operational performance. In this article, we will explore the value of the availability metric when calculating Overall Equipment Effectiveness (OEE) and the essential key metrics for measuring availability in Plex. We will also provide a step-by-step guide on how to calculate manufacturing availability and analyze its impact on production efficiency. Additionally, we will discuss common challenges manufacturers face when calculating availability and how smart factory tools can be integrated to ensure accurate availability insights.
Value of Availability Metric When Calculating OEE
When calculating OEE, availability plays a crucial role as it measures the actual uptime of the manufacturing process and equipment. OEE is a comprehensive metric that evaluates the overall efficiency of production operations by considering availability, performance, and quality. Availability, as one of the three components of OEE, indicates the amount of time that equipment is available for production.
By accurately measuring manufacturing availability, manufacturers can uncover hidden losses caused by equipment breakdowns, changeovers, and scheduled maintenance. This metric enables manufacturers to prioritize maintenance tasks and implement preventive measures to minimize downtime and maximize the utilization of equipment.
Furthermore, a high availability metric not only signifies efficient equipment usage but also reflects positively on the overall productivity of the manufacturing process. It indicates that the equipment is consistently operational, leading to smoother production flow and meeting production targets effectively. Manufacturers can use availability data to identify patterns of downtime and make informed decisions to enhance operational efficiency.
Moreover, availability metric can also serve as a key performance indicator (KPI) for assessing the reliability of equipment and the effectiveness of maintenance strategies. By tracking availability over time, manufacturers can identify trends, predict potential issues, and proactively address maintenance needs. This proactive approach helps in reducing unexpected downtime, improving overall equipment effectiveness, and ultimately boosting the bottom line of the manufacturing operation.
Key Metrics for Measuring Availability in Plex
Measuring availability requires specific key metrics that provide an accurate representation of how efficiently equipment is utilized in the manufacturing process. Some of the essential metrics for measuring availability in Plex include:
- Overall operating time: This metric measures the total time during which the equipment is expected to operate, including scheduled production time and planned downtime for maintenance.
- Unplanned downtime: Unplanned downtime refers to unexpected equipment failures, breakdowns, or other unexpected events that result in a production stoppage.
- Planned downtime: Planned downtime represents the time allocated for routine preventive maintenance, changeovers, or other scheduled events that temporarily halt production.
By monitoring and analyzing these key metrics, manufacturers can assess the availability of their equipment accurately and identify opportunities to improve productivity and reduce downtime.
Moreover, in addition to the key metrics mentioned above, another crucial factor in measuring availability in Plex is the concept of Mean Time Between Failures (MTBF). MTBF is a metric that calculates the average time elapsed between one failure of a piece of equipment and the next. It provides valuable insights into the reliability of the machinery and helps in predicting potential failures before they occur.
Furthermore, an often overlooked but significant metric for measuring availability is Mean Time to Repair (MTTR). MTTR measures the average time it takes to repair a piece of equipment after a failure has occurred. By tracking MTTR, manufacturers can optimize their maintenance processes, reduce repair times, and ultimately minimize production disruptions.
Step-by-Step Guide to Calculating Availability in Plex
Calculating manufacturing availability in Plex involves a systematic approach that ensures accuracy and reliability. Here is a step-by-step guide to help you calculate manufacturing availability:
Step 1: Access Plex ERP
- Log in to Plex: Use your credentials to access the Plex Manufacturing Cloud system. Your user role will determine which modules and features you have access to.
- Navigate to the Production 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:
- Run Time: This is the total time that the production equipment was actively running and producing goods.
- Navigate to the Production Tracking or Machine/Production Monitoring section within Plex.
- Select the relevant production job or work center.
- The Run Time can be found in the Production Activity records, where the system logs the actual time machines are in operation, often available in real-time.
- Planned Production Time: This is the total time scheduled for production, excluding planned downtime (e.g., scheduled maintenance, breaks).
- In the same Production Tracking section, locate the planned production time.
- Planned production time is typically established during the job scheduling phase and can be found in the Work Center Schedule or Job Schedule details.
Step 3: Perform the Calculation
Once you have gathered the necessary data:
- Open a Calculator or Spreadsheet: While Plex might not automatically perform this specific availability calculation, you can do it manually or use a spreadsheet like Excel.
- Calculate Availability:
- Divide the Run Time by the Planned Production Time.
Step 4: Record and Analyze the Availability
- Document the Calculation: Record the calculated availability percentage in a report, spreadsheet, or directly into Plex if your system allows for custom fields or dashboard integration.
- Compare Against Targets: Evaluate the calculated availability against internal benchmarks or industry standards to assess the efficiency of your production processes.
- Investigate Variances: If the availability is lower than expected, use Plex’s reporting and analytics tools to investigate potential issues, such as unexpected downtime, delays in starting production, or equipment failures.
Step 5: Continuous Improvement
- Monitor Availability Regularly: Continuously track availability data to identify trends, recurring issues, or opportunities for improvement.
- Implement Process Improvements: Based on your analysis, take corrective actions such as optimizing work schedules, reducing unplanned downtime, or improving maintenance practices.
- Leverage Plex Features: Utilize Plex’s advanced features like Real-Time Production Monitoring, Advanced Analytics, and MES (Manufacturing Execution System) to automate data collection, streamline calculations, and improve the accuracy of availability tracking.
It is crucial to understand the factors that contribute to downtime in manufacturing operations. Unplanned downtime can be caused by various reasons, such as equipment malfunctions, power outages, or material shortages. By accurately tracking and analyzing these incidents, manufacturers can identify recurring issues and implement proactive measures to minimize their impact on production.
Furthermore, planned downtime plays a significant role in ensuring the longevity and efficiency of manufacturing equipment. Scheduled maintenance activities, including calibration, inspections, and part replacements, help prevent unexpected breakdowns and extend the lifespan of machinery. By incorporating predictive maintenance strategies, manufacturers can optimize their production schedules and reduce the risk of costly disruptions.
Analyzing the Impact of Availability on Production Efficiency
The availability metric has a direct impact on production efficiency. By analyzing the availability of manufacturing equipment, manufacturers can identify bottlenecks and areas of improvement. High availability indicates that equipment is operating optimally, minimizing disruptions and maximizing productivity.
Conversely, low availability suggests a need for maintenance, process optimizations, or investments in new equipment. By addressing availability issues, manufacturers can reduce downtime, improve throughput, and enhance overall production efficiency.
Moreover, monitoring availability can also provide valuable insights into the reliability of equipment. A consistently high availability rate over time indicates that the machinery is robust and well-maintained, leading to greater predictability in production schedules and reduced risk of unexpected breakdowns.
Furthermore, tracking availability metrics can help in strategic decision-making regarding equipment upgrades or replacements. By understanding the availability trends and patterns, manufacturers can allocate resources effectively to ensure continuous operation and meet production targets efficiently.
Common Challenges in Calculating Availability
Calculating manufacturing availability in Plex can pose challenges for manufacturers. Some common challenges include:
- Inaccurate data: Lack of accurate data collection methods or reliance on manual data entry can lead to inaccurate availability calculations.
- Complex production processes: Manufacturing processes involving multiple stages and equipment make it complex to determine availability metrics accurately.
- Data integration: Integrating data from various sources, such as production monitoring systems and maintenance databases, can be challenging.
Addressing these challenges requires implementing robust data collection systems, leveraging automation technologies, and integrating data from different sources to ensure accurate availability calculations.
Furthermore, another significant challenge in calculating manufacturing availability is the impact of unplanned downtime. Unforeseen equipment failures, maintenance delays, or unexpected production issues can significantly affect the availability of manufacturing processes. This unpredictability adds another layer of complexity to availability calculations and requires proactive maintenance strategies to minimize downtime.
The dynamic nature of manufacturing environments can also pose challenges in availability calculations. Fluctuating demand, production schedule changes, and varying resource availability can all influence the overall availability of manufacturing operations. It is essential for manufacturers to continuously monitor and adjust their availability calculations to adapt to these dynamic factors and optimize production efficiency.
Integrating Smart Factory Tools for Accurate Availability Insights
To overcome the challenges and enhance availability insights, manufacturers can integrate smart factory tools into their operations. These tools leverage advanced technologies such as Internet of Things (IoT) devices, machine learning algorithms, and real-time analytics for accurate data collection and analysis.
By harnessing the power of smart factory tools, manufacturers can monitor equipment status in real-time, detect anomalies, predict failures, and optimize maintenance schedules. This proactive approach ensures maximum uptime, improved availability, and increased overall productivity.
Moreover, the integration of smart factory tools also enables manufacturers to implement predictive maintenance strategies. By analyzing historical data and equipment performance trends, these tools can predict when maintenance is required before a breakdown occurs. This predictive maintenance approach not only minimizes unplanned downtime but also extends the lifespan of machinery, reducing overall maintenance costs.
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. By measuring availability accurately and analyzing its impact, manufacturers can identify opportunities for improvement and optimize their operational performance. By overcoming common challenges and leveraging smart factory tools, manufacturers can ensure accurate availability insights and drive continuous improvement in their manufacturing processes.
Ready to enhance your manufacturing availability and take your production efficiency to the next level? Mingo Smart Factory offers a seamless, easy-to-use solution that’s quick to implement and designed to grow with your operations. With our plug-and-play productivity platform, you can start optimizing your processes in days, not months. Mingo’s customizable tools and direct equipment connectivity, coupled with no need for dedicated IT support, empower your manufacturing team to excel. Discover how Mingo can transform your operations and provide the insights you need for continuous improvement. Talk to an Expert today and unlock the full potential of your manufacturing capabilities.
