Installation, connectivity and testing for production line OEE from Express Data
Overall Equipment Effectiveness (OEE) is the benchmark for measuring and optimising manufacturing productivity.
It identifies the percentage of truly productive manufacturing time, with a 100% OEE score meaning you are only producing good parts at maximum speed with no stop time.
At Express Data, we install and connect OEE systems for a wide range of customers, delivering real-time visibility of performance alongside extensive data reporting and analysis.
In this article, we look at how overall equipment effectiveness solutions can be installed for a range of products, taking for example a large domestic or commercial door.
Why install overall equipment effectiveness solutions?
Production lines and assembly lines are a key part of many manufacturing processes – but unless their efficiency is monitored, you cannot know whether you are getting the best from your equipment. Express Data supplies and installs the XL Productivity Appliance for overall equipment effectiveness production monitoring and performance management.
XL Productivity Appliance is a cloud-based and on-premise system providing real-time visibility of the products rolling off your production line. A live scoreboard monitors productivity, downtime and changeover time, and can be customised to your own performance metrics. This means that operators and supervisors can take corrective action instantly if overall equipment effectiveness starts to dip.
However, the real benefit comes from qualitative reporting and analysis, giving detailed insights that identify the root cause of any delay. Acting on this information can quickly lead to improved productivity and profitability.
Purpose built overall equipment effectiveness solutions for any production line
Premdor, a UK manufacturer of timber doors, asked us to install and connect an OEE system to monitor a new production line for finishing their doors at their extensive manufacturing plant in Barnsley, South Yorkshire.
Express Data’s OEE solution can be adapted to fit a wide range of production or assembly lines, whatever the size and shape of your product – we have installed OEE production line systems for over 100 different products, from food to furniture. In this case, we planned and carried out the installation and network connectivity of the XL810 Productivity Appliance in just two days.
Installed database
The XL810 Productivity Appliance is a ‘black box’ consisting of a database, a server and a display wallboard. It contains all the information necessary to monitor the performance of each individual line, based on the expected output and throughput.
We installed Premdor’s XL Productivity Appliance at an appropriate location on the production line, making sure that it was visible to all and that the physical layer (including fibre or copper cabling) was suitable for the purpose and located away from potential sources of heat or damage.
Data sources
Data input to the XL Productivity Appliance is from IoT devices such as sensors, scales and hand-held scanners. We assess the customer’s requirements and select the appropriate input on the production line according to the product and environment. For Premdor, the size and array of data sensors was selected to work effectively with the length of the doors (around 2m) on the line, and mounted in the best orientation to capture each single unit.
Network connectivity
Once the hardware was installed, each data source was connected to the XL Productivity Appliance by Serial or ethernet connections. The equipment was connected to the network and an IP address allocated: no software installation is required, as access to data and reporting is all online.
The data and insights provided by our overall equipment effectiveness solution can be adapted to ensure they measure the exact detail you need for your specific product and line. Monitoring data and reports for Premdor are now easily accessed via the network at their premises from any tablet, smartphone or network-enabled device, and can also be accessed remotely.
Installation by experts
The design of many buildings can make it difficult to access and install the network infrastructure required for overall equipment effectiveness solutions. Express Data have professional experience in a wide range of challenging environments, so we can install your OEE productivity appliance quickly and efficiently.
Installation in high buildings
At Premdor, the height of the building could have presented difficulties for a less experienced team. The high apex meant that we were working at height to install the hardware to deliver power and network connectivity to the whole system.
Installation in large premises
At around 200m x 100m, the size of Premdor’s building meant that it was not possible to run data cabling direct to their Comms Room. Instead, we connected the new overall equipment effectiveness unit to the appropriate local area cabinet, ensuring that all cabling and materials were fit for purpose.
Testing the overall equipment effectiveness system and network connectivity
At Express Data we always make thorough checks to ensure that our network installation, network connectivity and each connected component is performing efficiently. Our end-to-end delivery of your OEE XL Productivity Appliance ensures robust performance and optimal efficiency for your specific needs.
Express Data: expert installation of overall equipment effectiveness solutions
Express Data is a specialist provider of network infrastructure and overall equipment effectiveness solutions. We have expert teams of engineers providing planning and on-the-ground support, delivering your project from start to finish.
If you would like to know more about how Express Data can help you eliminate inefficiency, reduce costs, improve profitability and provide fast ROI through OEE system installations, please get in touch.