Getting Started with the ArchFX Process Capacity Analysis Report

The Process Capacity Analysis Report (formerly known as the Process Capacity Based Sessions Report) enables you to view performance for all P&P machines of a particular vendor type (ASM, Fuji, etc.) at a site to identify opportunities for performance improvements. The report lets you:

• identify underutilized lines that spend too much time in the "Idle" state
• view the performance impact of Engineering activities and line Changeovers
• see how efficiently a Line operates across all Recipes during a time period (and the breakdown of various sources of loss)
• see how efficiently a particular Recipe runs on one or more Lines during a time period (and see the breakdown of sources of loss for that Recipe)

You can view the report in your browser and download it as a CSV file for further analysis in other tools.

Depending on your product plan, configuration, site, and job role, you may not have access to every report. If you don't see this report in your list of reports and need access, email help@archsys.io. Please include your name, job title, full international phone number, site name, the name of the report, and why you want access.

How to generate the sessions report for a site and P&P vendor type

1. Log in to ArchFX Cloud

2. Click Operational Insights:

3. Next to the entry for "Process-Capacity-Based Sessions Report (Basic)," click the Go button:

4. Enter the Title you want to use for the report (SITENAME-VENDOR-STARTDATE-to-ENDDATE is a good format), the Site, the Machine Vendor (e.g. ASM or Fuji), the Start date, and the End date for the report, and click Generate:

If your site has a mixture of P&P machines from different vendors, you'll need to run one sessions report for each vendor's machines.

If you want to look at the same time period within the Sessions Report and the ArchFX Live Dashboards, set the report duration to the last seven days. ArchFX Live Dashboards keep data for the last seven days.

Depending on the time of day you run the Sessions Report and the size of your site, it will take 5-20 minutes for the report to finish. During that time, it will be listed as "Generating ..." on the screen you see after clicking "Generate" and as "Scheduled ..." in the list of reports. Once it's finished, it will be listed as "Completed" and you can open it.

On the "Performance of Production Sessions" chart, look for large chunks of productivity loss. For example, in the below chart, you can see that Lines 23 and 25 have a lot of Operations (Ops) Loss, while Lines 17 and 2 have a lot of Upstream Loss (caused by machines before the P&Ps). So the sessions report begins to give you insights about WHY a line has low utilization.

Performance of Production Sessions

In the above screen shot:

• Performance is the time during which the line is building product.
• Transfer Loss is due to excessive time (more than rated transfer speed) spent on transferring units from one machine to another. For Fuji, we calculate the per-panel time spent in the loading state as reported by Fuji. If there is a distribution of values for a given program, we select an appropriate average representative value. For ASM, we assume 0.
• Upstream Loss is structural recurring loss caused by machines before the P&Ps.
• Downstream Loss is structural recurring loss caused by machines after the P&Ps.
• External Loss is caused by machines other than P&Ps, but it couldn't be determined whether it was Upstream or Downstream.
• Operational Loss ("Ops") is due to fluctuations in the performance of the line that cause Mean Takt Time for the Line to be greater than Line Achievable Takt Time. Includes various potential causes that are not broken out individually such as machine stops, transient upstream Problems (starvation) or downstream problems (blocking) that don't consistently recur, slow cycles, and uneven cycles.

Production vs Non-Production Time

In the above screen shot:

• Production is the time the line spends actively building the product
• Changeover is time spent changing between recipes
• Engineering time is time spent on line configuration, maintenance, etc.
• Idle time is when the line is not producing any product
• Unknown is time the sessions report was unable to categorize

Overall Summary of Activity

In the above screen shot:

• Run Hours is the sum of time spent by the Line in production sessions
• Sessions is the number of distinct sessions during the period of the report
• Recipes is the number of distinct recipes seen on the Line during the period
• Total Panels is the number of panels the Line produced during the period
• The values for Performance, Transfer, External, Upstream, Downstream, and Operations come from the "Performance of Production Sessions" chart. Performance + Transfer + External + Upstream + Downstream + Operations = 100%
• The values for Production, Engineering, Changeover, Idle, and Unknown come from the "Production vs Non-Production Time" chart. Production + Engineering + Changeover + Idle + Unknown = 100%.

Individual Production Sessions

In the above screen shot:

• You use the buttons with the Line names to select the Lines for which you wish to display the individual sessions.
• Hours is the total hours for that session.
• Panels is the total panels produced by that session.
• Performance is the percentage of the Golden Cycle Time that session achieved.
• Transfer time, Upstream loss, Downstream loss, External loss, and Operational loss are displayed for the individual session.

Enabling vendor software versions

• For ASM, you must be running ASM OIB Core version 5.5 or later to obtain full functionality from the sessions report. (If you are running a lower version, the sessions report may be unable to differentiate between Upstream Loss and Downstream Loss and may record all Upstream and Downstream loss as "External.")

Related documents

• Getting Started with Using ArchFX Tools to Optimize SMT Line Performance