Summary: The ArchFX React Production Overhead Display (OHD) enables line operators to see the most pressing information about production status on their line including whether the line is running or down, current product name, performance and quality statistics, a list of the worst feeders and nozzles on the line, and which machines are running, idle, or down.
You use these filters to select which Line you want to view:
- Site: Select the site you want to view.
- Area: Select the area(s) you want to view (or "All" for all areas).
- Line: Select the line(s) you want to view (or "All" for all lines) in line-oriented use cases.
The large line status panel makes it easy to see from a distance whether the line is running, idle, or experiencing a downtime.
The job data panels show you the name of the current product being built, the number of Components Per Hour (CPH) being placed, the Target Takt for the job, and the Actual Takt.
- CPH is the actual number of components that have been placed by Pick and Place machines on the line in the last 60 minutes.
- Target Takt Time is the expected time to build each unit of product that was entered by the operator when the job was created.
- Actual Takt is a moving average of the last ten completed takt times observed on the line. The duration of each time includes any downtimes during that cycle that were shorter than the "Minor Downtime" threshold (because those are treated as speed loss, counting against Performance), but excludes the time consumed by "regular" downtime events (which are counted as Availability loss).
Units Per Hour Per Shift
This panel shows you the number of Units Per Hour produced during the current shift. The target takt time is shown as a red dotted line.
For hours before the current hour, the panel charts what the target was for that hour (red dotted line) and what the actual production in units was during that hour (blue bar).
If there is more than one job running during a single hour, the targets are averaged together. For example, if you have one job with target takt time of 60 seconds for the first 30 minutes of an hour (= target 30 units for that 30-minute period) and then you miraculously switch right away to another job that has target takt time 120 seconds (= target 15 units for that 30-minute period) then your target UPH for the hour is 45 units for the hour. Idle periods of course have target 0 since there is no job defining a target takt time.
For the current in-progress hour, the chart continuously adjusts both the target (how much should have been produced up to this point in the hour) and the units produced (how much was produced up to this point in the hour). For example, if it is 7:15 a.m. and a job with a 60 second cycle time has been running since before the start of the hour, Target as of 7:15 a.m. is 15, and UPH is however many units were actually produced during that 15 minute interval. If that job continues running for the rest of the hour, by the end of the hour, Target will have reached 60.
Last Refreshed, Start Time, and Time to Complete
- Last Refreshed shows the time at which the Production OHD was last updated (in the current time zone).
- Current Job Start Time shows the time in the current zone that the current job began.
- Time to Complete shows how much time it will take for the current job to be completed. It is calculated by dividing the remaining units to create for the current job by the current units per hour (which is derived by dividing 60 minutes by the Actual Takt Time in minutes).
The "Shift Performance" bar shows the breakdown of time on the shift between running time (green), idle time (yellow), planned downtime (blue), unplanned uncategorized downtime (dark red with hash marks), and unplanned categorized downtime (bright red).
The total "downtime" reported on this performance bar only includes the time consumed by automatically detected downtime events during the current shift, not by cycles that are slower than the target takt time but not slow enough to reach the "minor downtime" threshold (if defined) or the downtime detection threshold (if the "minor downtime" feature is not in use). (See What's the difference between downtime and time lost? for details.)
OEE, Availability, Performance, Quality, and Pass/Fail Data
Planned Production Time for the current shift is defined as the duration of the current shift (so far) minus the total duration of any planned downtimes reported by operators for the current shift. This value is not shown but is used internally in calculating OEE.
Availability is Run Time divided by Planned Production Time, expressed as a percentage.
Run Time includes:
- production cycles that were at or ahead of target takt time
- slow cycles (that were slower than the target takt time, but not slow enough to reach the Downtime Threshold)
- “minor downtimes” (shorter than the Minor Downtime Threshold) that are treated as speed loss (reducing Performance) rather than as downtime (reducing Availability).
Run time does not include idle time.
Performance is "Net Run Time" divided by Run Time (summed across all jobs during the shift).
Net Run Time = Run Time - Performance Losses.
Performance Losses are calculated for each job as follows:
- “expected time” = throughput * target takt time
- "actual time" = end time - start time
- "total regular downtime duration" = the total duration of all regular downtimes during the job (excluding slow cycles and minor downtimes)
- Performance Losses = "actual time" - "expected time" - "total regular downtime duration"
The Quality panels show data sourced from the chosen quality machine on the line, which is typically the last AOI on the line that has a software connector installed, but can also be a different quality machine if desired.
- "Failed" shows the number of "fail" events that were recorded.
- "Passed" shows the number of "pass" events that were recorded.
- The Quality panel shows the the number of passes divided by the total number of quality scans, expressed as a percentage..
The OEE panel shows the product of Availability * Performance * Quality for the current shift overall.
Worst Nozzles lists the nozzles on the line with the largest number of mispicks from most mispicks downward.
Worst Feeders lists the feeders on the line with the largest number of mispicks from most mispicks downward.
The Line Diagram represents the status of each machine along the line by color:
- Green means that the machine is not showing an error code and has recently signaled a product completion event within a time period equal to twice the current cycle time for the machine.
- Yellow means that the machine is idle. It is not showing an error code, but it has not signaled a production completion event for a time period greater than twice the current cycle time for the machine.
- Red means that the machine is signaling an error code.
- Gray means that the machine does not have a hardware or software connector configured or React has received no data from the machine in the last hour, so React has no data about the machine's state.
The red caret (far right in the screen shot above) indicates the machine that is the current bottleneck for the line. On a well-balanced line, this will jump rapidly from machine to machine based on transient fluctuations in timing from machine-to-machine and cycle-to-cycle on a line that is in long-term balance; this behavior is normal. If on the other hand a particular machine is consistently the bottleneck, you will see the caret spend all or nearly all of its time on that machine.