How to Calculate Performance in SYSPRO

Accurately measuring and analyzing performance is crucial for success in the manufacturing industry. One such tool that plays a vital role in this process is SYSPRO, an enterprise resource planning (ERP) system. With its comprehensive features and functionalities, SYSPRO enables businesses to track and evaluate manufacturing performance effortlessly. In this article, we will delve into the value of performance metrics when calculating overall equipment effectiveness (OEE) and provide a step-by-step guide on how to calculate manufacturing performance in SYSPRO. We will also explore the common challenges faced in this process and discuss the integration of smart factory tools for more accurate performance insights.

Value of Performance Metrics When Calculating OEE

Performance metrics serve as the foundation for calculating Overall Equipment Effectiveness (OEE), a widely used measure in manufacturing efficiency. OEE encompasses three key components: availability, performance, and quality. Availability refers to the percentage of time a machine is running and available for production. Performance measures the speed at which the machine is producing goods compared to its maximum potential. Quality evaluates the number of good parts produced in relation to the total number of parts manufactured. By accurately calculating these components, businesses can gain valuable insights into their production processes.

It is essential for businesses to establish clear and consistent performance metrics to effectively measure OEE. By measuring machine availability, production speed, and product quality, manufacturers can identify bottlenecks, inefficiencies, and areas for improvement. This data-driven approach allows companies to streamline operations, reduce downtime, and enhance overall productivity.

With SYSPRO, a leading enterprise resource planning (ERP) software, manufacturers gain access to comprehensive reporting and analytics tools. These functionalities provide detailed insights into machine utilization, downtime reasons, production rates, and reject rates. By leveraging this data, businesses can make informed decisions to optimize production processes and maximize overall equipment effectiveness. Proactive monitoring of key performance metrics enables manufacturers to identify trends, implement corrective actions, and drive continuous improvement initiatives.

Setting Up SYSPRO for Accurate Performance Measurement

To ensure accurate performance measurement in SYSPRO, businesses first need to set up the system properly. This involves configuring the necessary modules, establishing performance metrics, and defining data collection methods.

1. Module configuration: Start by configuring the manufacturing and production modules in SYSPRO. This will enable you to accurately capture and analyze data related to production activities. Ensure that you also pay attention to other modules such as inventory management and procurement, as they play a crucial role in the overall performance measurement process.

2. Performance metric definition: Identify and define the performance metrics that are relevant to your manufacturing processes. This could include metrics such as machine uptime, cycle time, and reject rate. By clearly outlining these metrics, you can ensure consistency in measuring and tracking performance. Additionally, consider incorporating industry-specific KPIs to gain a comprehensive understanding of your operational efficiency.

3. Data collection: Establish robust data collection methods to capture real-time information from the shop floor. SYSPRO offers various data collection options, such as manual entry, barcode scanning, and machine integration. Choose the method that best suits your manufacturing environment and ensures accurate and timely data capture. Furthermore, explore the possibility of implementing IoT devices for automated data collection, which can streamline the process and minimize human error.

By following these steps and configuring SYSPRO accordingly, manufacturers can lay a solid foundation for accurate performance measurement and analysis. This meticulous setup not only enhances decision-making capabilities but also fosters a culture of continuous improvement within the organization, driving towards operational excellence and sustainable growth.

Step-by-Step Guide to Calculating Performance in SYSPRO

Step 1: Access SYSPRO ERP System

1. Log in to SYSPRO: Use your credentials to access the SYSPRO system. Your access level will determine which modules and features are available to you.
2. Navigate to the Manufacturing or Production Module: This module includes the necessary tools and data for managing and monitoring production activities, where you’ll find the information required for the performance calculation.

Step 2: Gather the Required Data

To calculate performance, you need three key data points:

1. Ideal Cycle Time: This is the standard time it takes to produce one unit under optimal conditions.
   • In SYSPRO, navigate to the Bill of Materials (BOM) or Work Center Operations.
   • Select the relevant part, product, or job.
   • The ideal cycle time is usually specified within the Operations or Routing section associated with that part.
2. Total Count: This is the total number of units produced during the run time.
   • Go to the Job Tracking or Work in Progress (WIP) section.
   • Find the specific job or work order 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 actual time the production equipment was running to produce the total count.
   • In the same job or production summary section, locate the Run Time data, often referred to as Actual Run Time or Production Time.
   • Ensure that this time only includes productive time and excludes any downtime or stoppages.

Step 3: Perform the Calculation

With the necessary data collected:

1. Open a Calculator or Spreadsheet: SYSPRO may not automatically calculate this specific performance metric, so you can perform the calculation manually or in a spreadsheet like Excel.
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 SYSPRO if your system has custom fields or dashboards for performance metrics.
2. Compare Against Targets: Evaluate the calculated performance against internal benchmarks or industry standards to determine if your production process is operating efficiently.
3. Investigate Variances: If the performance is lower than expected, use SYSPRO’s reporting and analytics tools to investigate potential causes, such as extended machine downtime, process inefficiencies, or operator-related issues.

Step 5: Continuous Improvement

1. Monitor Performance Regularly: Continuously monitor performance data to identify trends, recurring issues, or areas needing improvement.
2. Implement Process Improvements: Based on your findings, take corrective actions such as optimizing production processes, conducting preventive maintenance, or providing additional operator training to enhance performance.
3. Leverage SYSPRO‘s Advanced Features: Use SYSPRO’s features like Real-Time Shop Floor Data Collection or Manufacturing Operations Management to automate data collection, streamline calculations, and improve accuracy in tracking production performance.

Common Challenges in Calculating Manufacturing Performance

While SYSPRO offers valuable tools for performance measurement, there are several challenges that manufacturers may encounter during the process:

1. Data Accuracy

Ensuring the accuracy of data is crucial for reliable performance measurement. Incorrect data entry or inconsistent data collection methods can lead to inaccurate insights. Regular data validation and employee training can help mitigate this challenge.

Data accuracy is not only about the numbers but also about the context in which they are collected. Understanding the nuances of each data point and its relevance to the overall performance metrics is essential for making informed decisions. Implementing data governance practices and establishing clear data quality standards can further enhance the accuracy and reliability of performance data.

2. Data Integration

In complex manufacturing environments, data integration can be challenging. Integrating data from different sources and systems into SYSPRO may require additional resources and careful planning to ensure the accuracy and completeness of information.

Furthermore, data integration goes beyond just technical aspects; it also involves aligning data definitions, formats, and processes across various departments and systems. Establishing a data integration framework that outlines data mapping, transformation rules, and data flow processes can streamline the integration process and minimize errors.

3. Continuous Improvement Culture

An organization’s culture plays a vital role in leveraging performance measurement. A lack of emphasis on continuous improvement and data-driven decision making can hinder progress. Educating and involving employees in the performance measurement process can foster a culture focused on driving positive change.

Creating a continuous improvement culture requires more than just implementing performance metrics; it necessitates a shift in mindset towards embracing challenges as opportunities for growth. Encouraging cross-functional collaboration, recognizing and rewarding improvement efforts, and providing avenues for feedback and suggestions can nurture a culture that values innovation and excellence.

Integrating Smart Factory Tools for Accurate Performance Insights

To overcome the challenges associated with performance measurement, businesses can integrate smart factory tools and technologies. These tools leverage advanced analytics, machine learning, and internet of things (IoT) capabilities to provide real-time insights and predictive analytics.

By connecting production equipment, sensors, and systems to SYSPRO, manufacturers gain access to a wealth of data for performance measurement. Analyzing this data enables accurate identification of bottlenecks, prediction of downtime, and proactive decision making. Smart factory tools can also automate data collection processes, reducing manual errors and improving data integrity.

These tools empower manufacturers to embrace a proactive approach to maintenance. By monitoring equipment health and performance in real-time, potential issues can be identified and addressed before they escalate, minimizing downtime and maximizing overall equipment effectiveness.

What exactly are these smart factory tools and how do they work?

Let’s take a closer look.

One example of a smart factory tool is predictive maintenance software. This software uses machine learning algorithms to analyze historical data and identify patterns that indicate potential equipment failures. By detecting early warning signs, manufacturers can schedule maintenance activities in advance, preventing unexpected breakdowns and reducing costly downtime.

Another tool that can be integrated into the smart factory ecosystem is real-time performance monitoring systems. These systems collect data from various sources, such as sensors and production equipment, and provide real-time visibility into key performance indicators (KPIs). With this information at their fingertips, manufacturers can quickly identify areas of improvement and make data-driven decisions to optimize production processes.

In addition to these tools, the internet of things (IoT) plays a crucial role in the smart factory landscape. IoT devices, such as sensors and actuators, enable the seamless communication and integration of various components within the manufacturing environment. This connectivity allows for real-time data exchange, enabling manufacturers to monitor and control production processes remotely, improving efficiency and reducing costs.

Integrating Mingo Smart Factory

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

Integrating tools and technologies like Mingo Smart Factory into the manufacturing process can revolutionize performance measurement. By leveraging advanced analytics, machine learning, and IoT capabilities, manufacturers can gain real-time insights, automate data collection, and embrace a proactive approach to maintenance. These tools not only improve overall equipment effectiveness but also enable businesses to make data-driven decisions and stay competitive in today’s rapidly evolving market.

Ready to elevate your manufacturing performance with the power of smart factory tools? Mingo Smart Factory offers a seamless, plug-and-play solution that’s quick to implement and designed to grow with your business. Our platform is tailored for operational teams, eliminating the need for dedicated IT support, and can connect with any manufacturing equipment. Whether you’re looking to optimize your existing setup or integrate new hardware for data collection, Mingo is here to help. Don’t let complexity hold you back. Talk to an Expert today and discover how Mingo Smart Factory can transform your manufacturing operations with ease.