How to Calculate Performance in Plex

Manufacturing performance is a crucial aspect of any production operation. It allows businesses to measure and track their efficiency and productivity levels, identify areas of improvement, and ultimately optimize their manufacturing processes. Plex, a comprehensive manufacturing software solution, offers various tools and features to help businesses calculate their manufacturing performance accurately.

Value of Performance Metric When Calculating OEE

One of the fundamental metrics used to measure manufacturing performance is Overall Equipment Effectiveness (OEE). OEE takes into account three key factors: availability, performance, and quality. By calculating OEE, businesses can assess the effectiveness of their equipment and identify bottlenecks or inefficiencies that may be hindering their overall productivity.

When calculating manufacturing performance in Plex, it is essential to understand the value of this metric. OEE provides a holistic view of the performance of individual machines, production lines, or the entire manufacturing process. It enables businesses to pinpoint specific areas where improvements can be made, such as reducing downtime, increasing throughput, or improving product quality.

Moreover, OEE can also serve as a benchmarking tool, allowing companies to compare their performance against industry standards or best practices. This comparative analysis can help organizations set realistic performance goals and track their progress over time. Additionally, by breaking down OEE into its three components – availability, performance, and quality – businesses can delve deeper into the root causes of inefficiencies and develop targeted strategies for improvement.

Furthermore, the real-time monitoring capabilities of OEE software provide instant visibility into production performance, allowing operators and managers to make data-driven decisions on the shop floor. This proactive approach to performance management can lead to increased overall equipment effectiveness, reduced operating costs, and enhanced competitiveness in the market.

Step-by-Step Guide to Calculating Performance in Plex

Step 1: Access Plex Manufacturing Cloud

1. Log in to Plex: Use your credentials to access the Plex Manufacturing Cloud. Depending on your role and permissions, you will have access to different modules and features.
2. Navigate to the Production Management Module: This module contains tools and data necessary for managing and monitoring production activities, where you’ll find the information required for performance calculation.

Step 2: Collect the Required Data

To calculate performance, you need three essential data points:

1. Ideal Cycle Time: This is the standard time required to produce one unit under optimal conditions.
   • In Plex, go to the Routing or Process Routing section.
   • Select the relevant part or product.
   • The ideal cycle time is typically defined in the operation steps or routing details for the specific part.
2. Total Count: This is the total number of units produced during the run time.
   • Navigate to the Production Tracking or Shop Floor Control section.
   • Select the specific production order or job you are analyzing.
   • The total count (quantity produced) can be found in the Job Details or Production Summary section.
3. Run Time: This represents the total time the production equipment was actively running to produce the total count.
   • In the same job or production summary section, locate the Run Time data, often labeled as Actual Run Time or Production Time.
   • Ensure that this time reflects only the active production time, excluding any downtime or stoppages.

Step 3: Perform the Calculation

Once you have gathered the necessary data:

1. Open a Calculator or Spreadsheet: While Plex provides a wealth of data, you may need to perform this specific calculation externally, such as in Excel or using a calculator.
2. Calculate Performance:
   • Multiply the Ideal Cycle Time by the Total Count.Divide the result by the Run Time.

Step 4: Record and Analyze the Performance

1. Document the Calculation: Record the calculated performance percentage in a report, spreadsheet, or directly into Plex if your system has custom fields or dashboards for tracking performance metrics.
2. Compare Against Standards: Evaluate your calculated performance against internal targets or industry benchmarks to determine if your production process is operating efficiently.
3. Identify Issues: If the performance is below expectations, use Plex’s robust reporting and analytics tools to identify potential causes, such as machine downtime, inefficiencies, or quality issues.

Step 5: Continuous Improvement

1. Monitor Performance Regularly: Continuously monitor performance metrics to identify trends, recurring issues, or areas needing improvement.
2. Implement Improvements: Based on your findings, implement corrective actions such as equipment maintenance, process optimization, or operator training to enhance performance.
3. Utilize Plex’s Advanced Features: Consider using Plex’s advanced modules like Manufacturing Execution System (MES) or Real-Time Production Monitoring to automate data collection, streamline calculations, and improve the accuracy of performance tracking.

Utilizing Plex’s Reporting Tools for Performance Insights

Plex offers a range of reporting tools that enable businesses to generate valuable insights into their manufacturing performance. These tools provide detailed visualizations and analytics capabilities, making it easier to identify trends, patterns, and outliers in the data.

By utilizing Plex’s reporting tools, businesses can quickly and accurately assess their manufacturing performance. They can generate real-time reports and dashboards that highlight key performance indicators, enabling managers and operators to make data-informed decisions and take timely actions to improve efficiency and productivity.

One of the key features of Plex’s reporting tools is the ability to customize reports to suit specific business needs. Users can create personalized dashboards that display relevant metrics and KPIs, allowing for a more focused analysis of performance data. This customization empowers businesses to track the metrics that matter most to them, leading to more targeted insights and actionable intelligence.

Plex’s reporting tools offer advanced data visualization capabilities, including interactive charts, graphs, and heat maps. These visualizations not only make it easier to interpret complex data sets but also enhance the overall user experience by providing a more engaging and intuitive way to explore performance metrics. With the ability to drill down into detailed data points and trends, users can uncover hidden patterns and correlations that may have otherwise gone unnoticed.

The Role of Real-Time Data in Performance Measurement

Real-time data plays a crucial role in measuring manufacturing performance accurately. With Plex, businesses can capture and analyze real-time data from various sources, including machines, sensors, and other connected devices. This enables them to have up-to-the-minute insights into their production processes, identify bottlenecks or issues in real-time, and take immediate corrective actions.

By leveraging real-time data, businesses can proactively manage their manufacturing performance. They can monitor key metrics continuously, spot deviations from desired targets, and implement timely interventions to ensure optimal performance.

Real-time data also empowers businesses to enhance their predictive maintenance strategies. By analyzing data streams in real time, companies can detect patterns that indicate potential equipment failures before they occur. This proactive approach helps prevent costly downtime and maintenance issues, ultimately improving overall operational efficiency.

The utilization of real-time data in performance measurement extends beyond the shop floor. Businesses can integrate this data with their supply chain management systems to gain end-to-end visibility into their operations. This integration allows for better demand forecasting, inventory management, and overall supply chain optimization, leading to improved customer satisfaction and increased profitability.

Integrating Mingo Smart Factory for Accurate Performance Insights

How many steps does it take to calculate performance within the Mingo Smart Factory dashboard? The answer is one.

Plex provides integration capabilities with third-party tools like Mingo Smart Factory, which further enhance the accuracy and depth of performance insights. These tools can integrate with Plex’s reporting capabilities, enabling businesses to leverage additional features and functionalities for advanced performance measurement and analysis.

Mingo Smart Factory, for example, offers real-time monitoring, predictive analytics, and machine learning capabilities. By integrating this tool with Plex, businesses can gain deeper insights into their manufacturing performance, identify hidden patterns or correlations, and make data-driven decisions to drive continuous improvement.

Moreover, the integration of Mingo Smart Factory with Plex opens up avenues for proactive maintenance strategies. By utilizing the predictive analytics features of Mingo Smart Factory, manufacturers can anticipate equipment failures before they occur, thus minimizing downtime and optimizing production schedules. This proactive approach not only enhances operational efficiency but also reduces maintenance costs in the long run.

Schedule a Live Demo with Mingo Smart Factory

The collaboration between Plex and Mingo Smart Factory enables seamless data flow between different manufacturing systems. This interoperability ensures that relevant performance data is shared across various departments in real-time, fostering a collaborative environment where decisions are based on a holistic view of the manufacturing process. By breaking down data silos and promoting cross-functional communication, businesses can streamline operations and respond swiftly to changing market demands.

Ready to elevate your manufacturing performance to the next level? Mingo Smart Factory is here to streamline your operations with our easy-to-use, rapidly deployable system. Don’t let complex installations hold you back—Mingo is designed to be a plug-and-play solution that fits your unique manufacturing needs without the requirement for dedicated IT support. Whether you’re looking to connect to existing equipment or need hardware for legacy machines, Mingo has you covered. Take the first step towards unmatched productivity and Talk to an Expert today to discover how Mingo Smart Factory can transform your operations.