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How to Calculate OEE in Syspro

Overall Equipment Effectiveness (OEE) is a crucial metric in assessing the efficiency and productivity of manufacturing operations. By measuring OEE, businesses can identify areas for improvement and optimize their processes to maximize efficiency. Syspro, a leading enterprise resource planning (ERP) software, offers robust functionality for OEE calculation. In this article, we will explore how to calculate OEE in Syspro and the best practices for achieving accurate results.

Understanding Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness (OEE) is a performance metric that provides a comprehensive view of equipment performance by measuring three key factors: Availability, Performance, and Quality. It allows businesses to analyze their manufacturing process and identify areas for improvement.

The OEE formula is calculated by multiplying the availability, performance, and quality factors. Availability refers to the amount of time equipment is available for production, Performance measures the speed at which the equipment operates, and Quality assesses the number of quality products produced.

Understanding each of these factors in detail is crucial for optimizing equipment performance and maximizing productivity.

Availability:

The availability factor calculates the percentage of time that equipment is available for production. It takes into account planned and unplanned downtime. Planned downtime includes scheduled maintenance, changeovers, and other planned events that require the equipment to be offline. Unplanned downtime, on the other hand, refers to unexpected breakdowns, equipment failures, or any other unforeseen events that cause the equipment to be out of operation.

By accurately measuring availability, businesses can identify the root causes of downtime and take proactive steps to minimize it. This can involve implementing preventive maintenance programs, improving equipment reliability, and optimizing production schedules to reduce changeover times.

Performance:

The performance factor measures the actual production rate of the equipment compared to its maximum potential rate. It takes into account factors such as equipment speed, cycle time, and minor stoppages. Minor stoppages refer to short interruptions in production, such as equipment jams or material shortages, that can cause small delays.

To optimize performance, businesses can focus on reducing cycle times, improving equipment efficiency, and implementing lean manufacturing principles. By identifying and addressing bottlenecks, optimizing workflows, and streamlining processes, organizations can increase the overall performance of their equipment and achieve higher production rates.

Quality:

The quality factor measures the percentage of products that meet the required quality standards. It takes into account factors such as defects, rework, and scrap. Defects refer to products that do not meet the specified quality criteria, while rework involves repairing or modifying defective products to bring them up to standard. Scrap refers to products that are completely unusable and cannot be salvaged.

Ensuring high-quality production is essential for customer satisfaction and maintaining a competitive edge. By implementing robust quality control measures, businesses can reduce defects, minimize rework, and eliminate scrap. This can involve implementing statistical process control techniques, conducting regular quality audits, and providing training to employees to enhance their understanding of quality standards.

By understanding and optimizing these three factors – availability, performance, and quality – businesses can improve their overall equipment effectiveness and achieve higher levels of productivity, efficiency, and profitability.

Configuring Syspro for OEE Calculation

Syspro, a leading ERP system, provides a robust platform for calculating Overall Equipment Effectiveness (OEE). OEE is a key performance indicator used in manufacturing to measure the efficiency of production equipment. By configuring Syspro for OEE calculation, businesses can gain valuable insights into their operational efficiency and identify opportunities for optimization.

When configuring Syspro for OEE calculation, it is essential to consider the specific requirements of the manufacturing process. Different industries and production environments may have unique data points and parameters that need to be taken into account for accurate OEE calculation. By customizing Syspro to align with these specific needs, businesses can ensure that the OEE reports generated are tailored to provide actionable insights.

  1. Identify the relevant data points: Determine the key data points required for OEE calculation, such as machine uptime, production counts, downtime reasons, and scrap counts. These data points will provide the necessary inputs for the OEE calculation.
  2. Implement data collection: Set up mechanisms to collect the required data points automatically or manually. This can involve integrating Syspro with other software or implementing data collection tools.
  3. Define OEE calculation parameters: Configure Syspro to calculate OEE based on the defined parameters, such as production schedule, planned downtime, and quality standards.
  4. Generate OEE reports: Customize Syspro to generate OEE reports regularly, providing real-time insights into equipment performance and identifying areas for improvement.

By leveraging Syspro’s capabilities for OEE calculation, businesses can enhance their operational efficiency, optimize production processes, and ultimately improve their bottom line. The integration of OEE calculation into Syspro allows for a comprehensive analysis of equipment performance, enabling informed decision-making and continuous improvement initiatives.

Steps to Calculate OEE in Syspro

Calculating OEE in Syspro involves a series of steps that enable businesses to accurately assess equipment performance. Here are the steps to calculate OEE in Syspro:

  1. Collect relevant data: Gather the necessary data points, including production counts, machine uptime, downtime reasons, and scrap counts.
  2. Calculate availability: Divide the total operating time by the planned production time and multiply by 100 to calculate availability.
  3. Calculate performance: Divide the actual production rate by the maximum potential rate and multiply by 100 to calculate performance.
  4. Calculate quality: Divide the number of good products by the total number of products produced and multiply by 100 to calculate quality.
  5. Calculate OEE: Multiply the availability, performance, and quality factors to obtain the OEE percentage.

Once you have calculated the OEE percentage, it is essential to analyze the results to identify areas for improvement. For example, if the availability percentage is low, it may indicate issues with machine breakdowns or maintenance scheduling. Addressing these issues can help increase overall equipment effectiveness and productivity.

Furthermore, tracking OEE over time can provide valuable insights into equipment performance trends and help businesses make informed decisions about resource allocation and production planning. By regularly monitoring OEE in Syspro, organizations can optimize their manufacturing processes and enhance operational efficiency.

Best Practices for Calculating OEE in Syspro

To ensure accurate and meaningful OEE calculations in Syspro, it is important to follow best practices. Here are some recommended practices:

  • Standardize data collection: Implement standardized data collection processes to ensure consistent and reliable data inputs for OEE calculation.
  • Regularly review and update equipment data: Keep equipment data up to date to reflect any changes in equipment capabilities or production requirements.
  • Train employees on OEE calculation: Provide training to employees involved in data collection and analysis to ensure they understand the metrics and can accurately input data.
  • Continuously monitor and analyze OEE: Regularly review OEE reports and analyze the data to identify areas for improvement and implement appropriate actions.

Standardizing data collection processes involves creating clear guidelines for capturing relevant information, such as machine downtime, production counts, and quality data. By establishing consistent methods for data collection, organizations can minimize errors and discrepancies in OEE calculations, leading to more accurate performance evaluations.

Furthermore, updating equipment data in a timely manner is crucial for maintaining the integrity of OEE calculations. Changes in equipment settings, maintenance schedules, or production targets can significantly impact OEE results. By regularly reviewing and updating equipment data, organizations can ensure that OEE metrics reflect the most current operational conditions, enabling informed decision-making and performance improvements.

Challenges Calculating OEE in Syspro

While Syspro provides a robust platform for calculating Overall Equipment Effectiveness (OEE), businesses may encounter certain challenges in the process. OEE is a key performance indicator used to measure the efficiency of manufacturing processes by taking into account availability, performance, and quality.

Some common challenges faced by businesses when calculating OEE in Syspro include:

  • Lack of data standardization: Inconsistent data collection practices and lack of standardized data inputs can significantly impact the accuracy of OEE calculations. It is crucial for organizations to establish clear guidelines and protocols for data collection to ensure reliable OEE metrics.
  • Incomplete data collection: If certain data points are missing or not collected accurately, it can lead to incomplete OEE calculations, providing an incomplete picture of equipment efficiency. Regular audits and checks should be conducted to ensure all necessary data is being captured.
  • Data integration issues: Integrating Syspro with other software or data collection tools can present challenges if not properly configured. Seamless integration is essential to ensure that data flows smoothly between systems, enabling accurate OEE calculations.
  • Limited user knowledge: Insufficient understanding of OEE concepts and calculations among employees involved in the process can result in inaccurate inputs. Training programs and educational resources should be provided to enhance the OEE calculation proficiency of staff members, ultimately improving the accuracy of OEE metrics.

Advantages of Working with a Smart Factory System for OEE Calculation

A smart factory system offers several advantages when it comes to OEE calculation. Some key benefits include:

  • Automated data collection: Smart factory systems automate the collection of relevant data points, reducing the chances of data inaccuracies.
  • Real-time monitoring: With a smart factory system, businesses can monitor OEE in real-time, allowing for timely decision-making and intervention.
  • Advanced analytics: Smart factory systems often incorporate advanced analytics capabilities, enabling businesses to gain deeper insights into their OEE data.
  • Predictive maintenance: By leveraging IoT and machine learning, smart factory systems can help predict and prevent equipment breakdowns, minimizing downtime and optimizing OEE.

Calculating OEE in Syspro requires an understanding of the key metrics and configuration of the system to gather the necessary data. By following best practices, overcoming challenges, and embracing smart factory systems, businesses can effectively measure and improve their overall equipment effectiveness.

Ready to elevate your manufacturing efficiency with a system that’s easy to use and quick to implement? Look no further than Mingo Smart Factory. Our productivity platform is designed to fit seamlessly into your operations, offering a customizable, plug-and-play solution that’s up and running in no time. With Mingo, you won’t need dedicated IT support, as it’s built for manufacturing teams to manage effortlessly. Whether you’re looking to connect to existing equipment or need hardware for older machines, Mingo has you covered. Don’t let complexity slow you down. Talk to an Expert today and discover how Mingo Smart Factory can help you optimize your OEE and drive productivity to new heights.

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Alyxandra Sherwood
Digital Marketing Manager @ Mingo Smart Factory I Adjunct Professor @ SUNY Geneseo I Boston Marathoner I Second Street Award Winner I Media Professional with 15 Years Experience