Introduction to the PRIME "OEE Manager” Software

    "OEE Manager" is supplied free of charge to clients using PRIME's consultancy services, and at a very low cost to web-based customers

A fully-functioning demo copy of the software can be obtained by contacting PRIME by e-mail directly at prime00@talktalk.net and requesting a copy of the demo database (please mention in the e-mail how you were directed to the website)

The PRIME "OEE Manager” software is unique, in that it is designed for use in manufacturing companies to provide all of the features that are necessary to support continuous improvement processes, with the management of OEE (Overall Equipment Effectiveness) at the heart of the package. The software is designed to quantify all of the areas of loss involved in production operations, calculate Site, Department and Cell OEE values, and present the performance information at all levels, from strategic reporting for senior management down to the very detailed information needed to support good day-to-day manufacturing control. It is structured to support direct shopfloor data input where this is appropriate, but also has input screens for speedy input by a central clerk from shift report forms etc. Data can alternatively be imported from existing spreadsheets.

The software also incorporates standard CMMS functionality, covering work order management, preventive maintenance scheduling and stores control, although these functions can be hidden from the menus if desired. For manufacturers that employ non-fixed assets such as tooling or strategic spare capital plant, there is a Tooling Module that generates a full audit trail for these items. Operators and craftsmen sign on to tailored, abbreviated sets of menus set up for specific clients.

To complete the continuous improvement cycle, "OEE Manager" also incorporates a module for carrying out Failure Mode, Effect and Criticality Assessment (FMEA), specifically designed for a maintenance environment, and a Root Cause Elimination package for managing the continuous improvement process. 

All of the modules are inter-dependant, although they can be used on a standalone basis. For companies that are only interested in using the OEE features, this can be done without needing to set up for any of the other features. However, because of the integrated nature of the software, the FMEA outputs can be used directly to support PPM programmes if desired, or a refurbishment programme for tooling components can be triggered by production outputs measured in the OEE module. Alternatively, any of the features can be run independently (eg only work management, or PPM, or FMEA etc), and the other features hidden from the user menus.

                        (Click on the "Key Features" tab to obtain a summary of the functionality of "OEE Manager")

The system is based on the concept of Overall Equipment Effectiveness, and can be applied to virtually all types of manufacturing processes :

·          Discrete (one-off) manufacturing based on cycled production (eg press operations, injection moulding etc)

·          Flowline processing (eg continuous chemicals manufacture, soft drinks, bottling, extrusion processes etc)

·          Long cycle time batch production (eg batch chemicals production) etc  

   The software is totally based on Microsoft Access but is fully menu driven, requiring no knowledge of Access to be used. The menus are tailored to the authorities that are granted to individual users, and can be modified by the System Administrator, who has access to the full software design. The system comprises configuration tables that allow users to customise most of the features into their own terminology, user-friendly data input forms, and suites of reports that present both strategic level information in the form of graphs and tabular reports, and operational level reports. Users with knowledge of Access can prepare their own reports and attach them to the standard system menus.

The concept of Overall Equipment Effectiveness forms the basis of the design of the system, and is based on the standard understanding of the subject :

OEE % = Uptime Performance %  x  Efficiency %  x  Quality Performance %

This is modeled in OEE Manager on a shift basis, calculated and reported in the form of Daily, Weekly and Monthly OEE Performance graphs and reports.

In order to calculate OEE, the system collects the following core information :

·          The scheduled hours for each OEE cell (this is calculated automatically in "OEE Manager")

·          The time lost in downtime

·          The amount of material produced

·          The amount of material lost in rejects

Each of the separate areas of loss are collected at the lowest level of detail for the continuous improvement process, but aggregated for higher level and strategic level reporting, in both trend and summary form.

Outputs from the system fall into 5 distinct categories :

-    OEE Reports (OEE, Uptime, Efficiency and Quality reports, in Daily, Weekly or Monthly time bucket format). Also Period Strategic Performance Reports.

-    OEE Graphs (OEE, Uptime, Efficiency and Quality graphs, also in Daily, Weekly or Monthly time bucket format). Also Weekly Loss Charts and Engineering Downtime charts. Standard methods of exporting charts to Microsoft Excel are in place, for use in Word documents or Powerpoint presentations.

-    Downtime reports, at both summary and detailed levels, including cost of downtime.

-    Engineering downtime reports, also at both summary and detailed levels, incorporating analysis of engineering fault types and causes. Also, MTBF reports, work order and equipment cost reports, and craftsmen response time reports.

-    Production reports, also at both summary and detailed levels, including shift comparison reports,  and operator performance reports.

-    A suite of data entry forms and reports for management of a Root Cause Elimination programme,

"OEE Manager" contains 5 levels of security built in. For additional control, “OEE Manager” also includes integrated shop floor data collection for craftsmen and operator data input, with individual or group password protection, and with all data inputs registered against the sign-on user.

Additional Features

As well as the primary function of providing a management system for OEE improvement, the software contains CMMS (Computerised Maintenance Management System) capability, particularly designed for small/medium-sized manufacturing organisations, comprising :

                                    A Work Order management system

                                    A Preventive Maintenance management system

                                    An Engineering Spare Parts Control system

                                    A Tooling Management system

                                    A Projects/Modifications Management system

Additionally, there are 2 modules designed to provide a comprehensive, closed loop capability to use the loss information in the system to generate and manage an effective continuous improvement program. These modules comprise :

                                    A Failure Mode, Effects and Criticality assessment module

                                    A Root Cause Elimination module

Each of these sub-systems incorporate a suite of commonly-required reports.  

    A fully-functioning demo copy of the software can be obtained by contacting PRIME by e-mail directly at prime00@talktalk.net and requesting a copy of the demo database (please mention in the e-mail how you were directed to the website).

 Basic System Database Configuration

The system will run on any computer that is provided with Microsoft Access 2000 or later, and Microsoft Windows 98, XP, NT or Me. A processor of 1Mz or greater, and a RAM of 256k will produce good performance. The system is designed for loading on a system server, when the multi-site features will be enabled.

You can download a Powerpoint presentation that gives a very brief introduction to the software. However, please note that the software is being progressively upgraded, and the Powerpoint presentation will not necessarily show the current range of features. These are all available in the fully-functioning demo software that can be obtained by e-mail contact with PRIME at prime00@talktalk.net. To obtain the best view of the Powerpoint presentation, click on the link below, use the option to save to your computer, and open it via the Powerpoint slide view option.

Download presentation on " PRIME OEE Manager"

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