Overview
To calculate KPIs such as the availability or efficiency of a machine or plant, the respective times must be used. These can be derived from the MachineryItemState and the MachineryOperationMode. This annex does not define any KPI values. The assumption is, that the KPIs will be calculated application specific, but can be based on those two states. Potentially, more information is needed for calculating specific KPIs.
To calculate KPI often information about the planning of production is required. This information usually comes from a higher level system such as MES or ERP and not from the machine, so it has not been included in this specification.
The following table in C.2 is used to explain how the required KPI time elements can be derived conform to ISO 22400-2 using the combination of MachineryItemState, MachineryOperationMode and HLS-ConditionState of the higher level system such as MES or ERP on level 3 (see IEC 62264-1). The KPI element definitions used are taken from the ISO 22400-2:2022 called Automation systems and integration - Key performance indicators (KPIs) for manufacturing operations management for KPI calculation.
The following section C.3 provides an example interpretation, of how the MachineryOperationMode and MachineryItemState can be used to determine SEMI E10 [5] times. Typically, MachineryItems are scheduled by higher level systems and are not aware how they are scheduled. So, interpretations of SEMI E10 times are typically “Operations time”.
Example interpretation for ISO 22400
Table 53 proposes how KPI time elements according to ISO 22400-2 can be set using the combinations of MachineryItemState, MachineryOperationMode and HLS-ConditionState. These ISO 22400-2 KPI time elements can be used to do KPI calculations.
Table 53 – KPI time elements according to ISO 22400-2
|
ISO 22400-2 KPI time elements |
ISO 22400-2 Interpretation |
Machinery Item State |
Machinery Operation Mode |
Higher Level System Condition State |
|
ADET (Actual Delay Time)
|
Delay time |
OutOfService |
Processing |
System state is order registered but no maintenance |
Delay time |
NotAvailable |
Processing(last sent) |
System state is order registered but no maintenance |
Delay time |
NotExecuting |
None |
System state is order registered |
Delay time |
NotExecuting |
Processing |
System state is order registered but no maintenance and time is just out of cycle time |
|
ADOT (Actual Down Time) |
Down time |
OutOfService |
None |
System state is planned busy time based on operation calendar |
Down time |
NotAvailable |
None(last sent) |
System state is planned busy time based on operation calendar but no order registered |
Down time |
NotExecuting |
None |
System state is planned busy time based on operation calendar but no order registered |
|
APMT (Actual Preventive Maintenance Time)
|
preventive maintenance as service |
OutOfService |
Maintenance |
System state is planned operation time based on operation calendar but no order registered |
Setup time as service |
OutOfService |
Setup |
System state is planned operation time based on operation calendar but no order registered |
Setup time as service |
NotAvailable |
Setup(last sent) |
System state is planned operation time based on operation calendar but no order registered |
preventive maintenance as service |
NotAvailable |
Maintenance(last sent) |
System state is planned operation time based on operation calendar but no order registered |
preventive maintenance as service |
NotExecuting |
Maintenance |
System state is planned operation time based on operation calendar but no order registered |
Setup time as service |
NotExecuting |
Setup |
System state is planned operation time based on operation calendar but no order registered |
preventive maintenance as service |
Executing |
Maintenance |
System state is planned operation time based on operation calendar but no order registered |
|
APT (Actual production time) |
Production time |
Executing |
None |
System state is order registered |
Production time |
Executing |
Processing |
System state is order registered |
Production time |
NotExecuting |
Processing |
System state is order registered |
Production time |
Executing |
Setup |
SPLIT in setup time (AUST) and value added production time (APT=PQ*RPI) as retrograde confirmation (backflush) |
|
ASDT (Actual Shut Down Time) |
Shut down time |
OutOfService |
None |
System state is shut down time based on operation calendar |
Shut down time |
NotAvailable |
None(last sent) |
System state is shut down time based on operation calendar |
Shut down time |
NotExecuting |
None |
System state is shut down time based on operation calendar |
|
AUST (Actual Unit Setup Time)
|
Setup time |
OutOfService |
Setup |
System state is order registered |
Setup time |
NotAvailable |
Setup(last sent) |
System state is order registered |
Setup time |
NotExecuting |
Setup |
System state is order registered |
Setup time |
Executing |
Setup |
SPLIT in setup time (AUST) and value added production time (APT=PQ*RPI) as retrograde confirmation (backflush) |
|
TTR (Time to Repair) |
Delay time but maintenance |
OutOfService |
Maintenance |
System state is order registered but maintenance activities |
Delay time but maintenance |
OutOfService |
Processing |
System state is order registered but maintenance activities |
Delay time but maintenance |
NotAvailable |
Processing(last sent) |
System state is order registered but maintenance activities |
Delay time but maintenance |
NotAvailable |
Maintenance(last sent) |
System state is order registered but maintenance activities |
Delay time but maintenance |
NotExecuting |
Maintenance |
System state is order registered but maintenance activities |
Delay time but maintenance |
NotExecuting |
Processing |
System state is order registered but maintenance activities and time is out of cycle time |
Delay time but maintenance |
Executing |
Maintenance |
System state is order registered but maintenance activities |
Example interpretation for SEMI E10
The MachineryItemState OutOfService and the MachineryOperationMode Processing can be interpreted as SEMI E10 “Unscheduled Downtime”.
The MachineryItemState NotExecuting and the MachineryOperationMode Setup can be interpreted as SEMI E10 “Engineering time”.
The MachineryItemState NotExecuting and the MachineryOperationMode Processing can be interpreted as SEMI E10 “Standby time”.
The MachineryItemState Executing and the MachineryOperationMode Processing can be interpreted as SEMI E10 “Productive time”.
In this example, the availability of the Machine is calculated according to ISO 22400. For this purpose, the Actual Production Time (APT) and Planned Busy Time (PBT) are required. The APT can be derived from the combination of the MachineryItemState "Executing" and the MachineryOperationMode "Processing". Alternatively, the APT can also be derived from the Semi E10 time "Productive time". The PBT is usually not known to the Machine and is accordingly not provided by this specification.
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Bibliography
[1] ISO 12100:2010, Safety of machinery – General principles for design – Risk assessment and risk reduction
[2] IEC 61499-1:2012, Function Blocks – Part 1: Architecture
[3] OPC 40501-1, UA for Machine Tools Part 1: Machine Monitoring and Job Overview
(http://www.opcfoundation.org/UA/MachineTools/)
[4] OPC 40010-1, OPC UA for Robotics – Part 1: Vertical Integration
(http://www.opcfoundation.org/UA/Robotics/)
[5] SEMI E10, Specification for Definition and Measurement of Equipment Reliability, Availability, and Maintainability (RAM) and Utilization
[6] ISO 22400-2, Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 2: Definitions and descriptions
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