prEN 415-11

Safety of packaging machines - Part 11: Determination of efficiency and availability

This document is applicable for packaging machines falling within the scope of EN 415-1, referred to in the following as "machine systems". This document can also be applied by analogy to other related processing machines.
This document does not contain safety requirements.

Sicherheit von Verpackungsmaschinen - Teil 11: Ermittlung von Effizienz und Verfügbarkeit

Dieses Dokument gilt für Verpackungsmaschinen die in den Anwendungsbereich von DIN EN 415-1 fallen, nachfolgend vereinfacht Maschinensystem genannt. Dieses Dokument ist sinngemäß auch auf andere technisch verwandte Verarbeitungsmaschinen anwendbar.
Dieses Dokument enthält keine Festlegungen zu Sicherheitsanforderungen.

Sécurité des machines d'emballage - Partie 11 : Détermination de l'efficacité et de la disponibilité

Le présent document est applicable aux machines d’emballage entrant dans le domaine d'application de l’EN 415-1, ci-après désignées les "systèmes de machines". Le présent document peut également être appliqué par analogie à d'autres machines de traitement connexes.
Le présent document ne contient pas de prescriptions de sécurité.

Varnost pakirnih naprav - 11. del: Ugotavljanje učinkovitosti in razpoložljivosti

Standards Content (sample)

SLOVENSKI STANDARD
oSIST prEN 415-11:2020
01-oktober-2020

Varnost pakirnih naprav - 11. del: Ugotavljanje učinkovitosti in razpoložljivosti

Safety of packaging machines - Part 11: Determination of efficiency and availability

Sicherheit von Verpackungsmaschinen - Teil 11: Ermittlung von Effizienz und
Verfügbarkeit

Sécurité des machines d'emballage - Partie 11 : Détermination de l'efficacité et de la

disponibilité
Ta slovenski standard je istoveten z: prEN 415-11
ICS:
55.200 Pakirni stroji Packaging machinery
oSIST prEN 415-11:2020 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN 415-11:2020
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oSIST prEN 415-11:2020
DRAFT
EUROPEAN STANDARD
prEN 415-11
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2020
ICS 55.200
English Version
Safety of packaging machines - Part 11: Determination of
efficiency and availability

Sécurité des machines d'emballage - Partie 11 : Sicherheit von Verpackungsmaschinen - Teil 11:

Détermination de l'efficacité et de la disponibilité Ermittlung von Effizienz und Verfügbarkeit

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee

CEN/TC 146.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations

which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other

language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC

Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are

aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without

notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 415-11:2020 E

worldwide for CEN national Members.
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Contents Page

Introduction .......................................................................................................................................................... 4

1 Scope .......................................................................................................................................................... 5

2 Normative references .......................................................................................................................... 5

3 Terms, definitions and symbols ....................................................................................................... 5

3.1 Terms and definitions ......................................................................................................................... 5

3.2 Symbols ...................................................................................................................................................13

4 Key figures for describing the operating behaviour of machine systems ......................16

4.1 General ....................................................................................................................................................16

4.2 Calculation bases .................................................................................................................................17

4.3 General key figures for describing the operating behaviour ..............................................17

4.4 Technical key figures for describing the operating behaviour ..........................................17

5 System acceptance ..............................................................................................................................17

Annex A (normative) Time model ................................................................................................................19

Annex B (normative) Output model ............................................................................................................21

Annex C (normative) Minimum points to be agreed upon for the acceptance test ....................22

Annex D (informative) Acceptance protocol (determination of the technical efficiency E in

accordance with EN 415-11) ...........................................................................................................24

D.1 General information ...........................................................................................................................24

D.2 Acceptance test documentation .....................................................................................................26

Annex E (informative) Clarification of root-cause of incidents as prerequisite for the

calculation of key-figures according to EN 415-11 .................................................................28

E.1 Root cause clarification of incidents ............................................................................................28

E.1.1 Flow chart root cause clarification ...............................................................................................28

E.1.2 Technical root causes ........................................................................................................................30

E.1.3 Organizational root causes ..............................................................................................................31

E.1.4 Upstream and downstream of the machine observed ...........................................................31

E.2 Example for calculation of key figures according to Clause 4 of this document: Filling

line for beer cans .................................................................................................................................32

E.2.1 Description of machine system considered (Figure E.2) ......................................................32

E.2.2 Incidents observed during observation period .......................................................................33

E.2.3 Calculation of key figures for machine observed (here: filling block) .............................34

E.2.4 Calculation of key figures for can filling line .............................................................................38

E.2.5 Calculation of technical availability of integrated machine units (upstream and

downstream) ........................................................................................................................................41

Bibliography ........................................................................................................................................................45

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European foreword

This document (prEN 415-11:2020) has been prepared by Technical Committee CEN/TC 146 “Packaging

machines - Safety”, the secretariat of which is held by UNI.
This document is currently submitted to the CEN Enquiry.
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Introduction

The operation of packaging machines and packaging lines is subject to numerous influences on the part

of the machines and linking devices themselves, the upstream and downstream systems, the contents of

the packaging, the packaging, the auxiliary packaging, the production organization, the service and

maintenance personnel and the ambient conditions at the installation site. As a result, the packaging

process is not disruption-free. During the operation of the packaging machine or packaging line, periods

in which production takes place according to plan and to the required standard of quality stochastically

interchange with periods in which disruptions lead to losses (e.g. due to scrap or production stoppages).

This operating behaviour of a packaging machine or packaging line can be characterized by key figures,

established from partial times on the basis of the structure of the machine working time and the output

produced, or producible, during these periods.

This document defines a time model and an output model derived from this time model. These can be

used to define general key figures and technical key figures for describing the operating behaviour of

packaging machines and packaging lines. For this purpose, the technical key figures only take into

consideration lost time and output losses that can be attributed to each packaging machine or packaging

line examined.

Technical key figures are often based on agreed characteristics that are checked as part of an acceptance

test. In practice, the system boundaries forming the basis of the acceptance test and that of the

organizational and technical boundary conditions clearly influence the value determined for each key

figure. This document specifies requirements for the proper performance of an acceptance test, the

modalities of which should be agreed by the participating parties prior to the acceptance test being

carried out.
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1 Scope

This document is applicable for packaging machines falling within the scope of EN 415-1, referred to in

the following as “machine systems”. This document can also be applied by analogy to other related

processing machines.
This document does not contain safety requirements.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies. For

undated references, the latest edition of the referenced document (including any amendments) applies.

EN 415-1, Safety of packaging machines — Part 1: Terminology and classification of packing machines and

associated equipment
3 Terms, definitions and symbols
3.1 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at http://www.iso.org/obp
3.1.1
machine system
system

machines and lines with defined system boundaries regarding introduction of processing materials,

operating materials, the release of output units, waste or scrap
3.1.2
processing material

referring to packaging machines: contents of the packaging, packaging, auxiliary packaging or package

3.1.3
output unit
processing material after passing through the machine system

Note 1 to entry: A packaging process consists of sub-processes in accordance with the basic tasks of packaging (i.e.

forming, filling, sealing, wrapping) as well as the sub-tasks such as the cleaning of the packaging or labelling. In the

context of this document, the packaging process comprises the respective machine system with the defined system

boundaries. A output unit can be an intermediate product of the packaging process, a package or a loading unit.

3.1.4
acceptance
recognition of fulfilment of agreed characteristics of the machine system
3.1.5
acceptance test
test production to determine selected characteristics of the machine system
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3.1.6
acceptance period
agreed duration of an acceptance test
3.1.7
disruption

unplanned event that compromises or interrupts the production of quality output units

3.1.7.1
system related disruption
disruption that can be attributed to the machine system considered
3.1.7.2
disruption not related to system
disruption that cannot be attributed to the machine system considered
3.1.8
start-up time

time period from the start of the loading of the first element in the machine system to the point in time

when the first output unit leaves the final element of the machine system
3.1.9
emptying time

time period from the initiation of the production end of the machine system to the point in time when the

last output unit leaves the final element of the machine system
3.1.10
time category

summary of time periods with the same defined use characteristics for the considered machine system

3.1.10.1
theoretically available time
theoretically available time
Note 1 to entry: 24 h for seven days of the week.
3.1.10.2
idle time
time period in which the machine system cannot be scheduled for production
3.1.10.3
machine working time
time period in which the machine system is scheduled for production
3.1.10.4
scheduled down time

scheduled time without the production of output units (e.g. for scheduled cleaning, maintenance, repair,

equipping or adjustment of the machine system as well as product exchange)
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Note 1 to entry: Difference between machine working time and operating time.
3.1.10.5
operating time
time period scheduled for the production of output units by the machine system
3.1.10.6
unplanned down time
unplanned time without the production of output units due to a disruption

Note 1 to entry: Unplanned down time can be determined automatically or manually.

3.1.10.6.1
system related unplanned down time
sum of all system related unplanned down times
3.1.10.6.2
unplanned down time not related to system
sum of all non-system related unplanned down times
3.1.10.7
running time
time period in which the machine system produces
Note 1 to entry: The machine system can produce scrap during running time.
3.1.10.8
scrap time

sum of the times in which the machine system does not produce in a manner conforming to the required

standard of quality
Note 1 to entry: Mathematical variable.
3.1.10.9
performance loss time
running time minus the sum of quality time and scrap time
Note 1 to entry: Mathematical variable.

Note 2 to entry: All loss times that cannot be attributed to the time categories t and t are attributed to t .

LQ F LP

Note 3 to entry: This time category includes calculated loss times due to a reduced working speed as compared

with the set performance as well as scheduled and unscheduled times without performance that are not attributable

to disruptions (e.g. due to start-up or emptying times or supply of processing materials (contents of packaging,

packaging or auxiliary packaging)).
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3.1.10.10
quality time

time period in which the machine system produces in a manner conforming to the required standard of

quality
Note 1 to entry: Mathematical variable.
3.1.10.11
loss time
sum of unplanned down time, scrap time and performance loss time
Note 1 to entry: Mathematical variable.
3.1.10.11.1
loss time caused by machine system
sum of loss times that can be attributed to the machine system
3.1.10.11.2
loss time not caused by machine system
sum of loss times that cannot be attributed to the machine system

Note 1 to entry: The reasons can be of a technical nature (e.g. effects of upstream or downstream systems, technical

disruptions due to operating errors or packaging that does not comply with specifications) or of an organizational

nature (internal or external organizational causes). Organizational causes include e.g. a shortage of product or

packaging, unavailability of service or maintenance personnel, performance losses due to packaging or product

qualities that do not comply with specifications, power failures, shortages of supply media.

3.1.11
output
sum of all output units in a defined time period
3.1.11.1
quality output
output of output units conforming to quality produced in the operating time
3.1.11.2
scheduled output
scheduled quality output
Note 1 to entry: Planning variable.
3.1.11.3
agreed output
agreed output of output units conforming to quality in a defined time period
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3.1.11.4
manufactured output
actual output of produced output units including scrap
3.1.11.5
output losses
difference between scheduled output and quality output
Note 1 to entry: Mathematical variable.
3.1.11.5.1
output losses caused by machine system
output losses that can be attributed to the machine system
3.1.11.5.2
output losses not caused by machine system
output losses that cannot be attributed to the machine system
3.1.11.5.3
scrap output

output of produced output units that do not comply with the specified quality requirements

3.1.11.5.4
performance losses
difference between scheduled output and manufactured output
3.1.12
performance
output units per time unit
3.1.12.1
nominal performance
performance for which the machine system has been calculated and designed

Note 1 to entry: The nominal performance depends on the processing materials. Consequently, the machine

system can exhibit different nominal performances.
3.1.12.2
set performance
theoretical performance achievable at a set working speed of the machine system

Note 1 to entry: The set performance has an influence on the quality of the output units and the system stability.

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3.1.13
key figure
figure for the characterization of the use of a machine system

Note 1 to entry: Developed on the basis of use times, loss times and output losses that have been determined

empirically or by simulation.
3.1.13.1
general key figure

key figure for the calculation of which all relevant loss times and output losses are taken into

consideration

Note 1 to entry: No differentiation is made as to whether the determined loss times have been caused by the

considered machine system itself or by factors external to the system.
3.1.13.1.1
quality performance
quality output related to operating time
Note1 to entry: Corresponds to the previous key figure “operating performance”.
3.1.13.1.2
quality factor
ratio of quality output to manufactured output

Note 1 to entry: The quality factor is determined based on output and can be converted to a time-based variable.

3.1.13.1.3
running time factor
ratio of running time to operating time
3.1.13.1.4
performance factor
ratio of manufactured output to scheduled output

Note 1 to entry: The performance factor is determined based on output and can be converted to a time-based

variable.
3.1.13.1.5
availability
ratio of operating time to machine working time
Note 1 to entry: For technical availability see 3.1.13.2.2.
3.1.13.1.6
loading factor
ratio of machine working time to theoretically available time
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3.1.13.1.7
overall equipment effectiveness
OEE
ratio of quality time to machine working time
Note 1 to entry: Scheduled down time is taken into consideration.
3.1.13.1.8
efficiency

ratio of quality output to scheduled output at a constant set performance at the level of the nominal

performance of the considered machine system
Note 1 to entry: Scheduled down time is not taken into consideration.

Note 2 to entry: Unplanned down time and performance loss times are taken into consideration.

Note 3 to entry: E ≤ 1.
3.1.13.1.9
mean time to repair
MTTR

mean duration of disruption-related down time of the machine system within the operating time

Note 1 to entry: Key figure for the evaluation of the system stability based on empirical data.

Note 2 to entry: Determination of a safe mean value for MTTR is not possible within an implementable acceptance

period.
3.1.13.1.10
mean time between failures
MTBF

mean time elapsed between disruption-related down times of the machine system (time from the end of

the previous disruption to the start of the subsequent disruption) within the operating time

Note 1 to entry: Key figure for the evaluation of the system stability based on empirical data.

Note 2 to entry: Determination of a safe mean value for MTBF is not possible in the framework of an implementable

acceptance period.
3.1.13.2
technical key figure

key figure in the calculation of which output losses and loss times external to the system are not taken

into consideration
3.1.13.2.1
technical quality performance

ratio of quality output to operating time adjusted for loss time not caused by machine system

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3.1.13.2.2
technical availability
technical running time factor

ratio of running time to operating time adjusted for unplanned down time not related to system

Note 1 to entry: R ≥ E .
S S
Note 2 to entry: R = E for t = 0 and t = 0.
S S LP LQ

Note 3 to entry: The technical availability takes into consideration neither performance losses nor scrap output.

3.1.13.2.3
technical efficiency

ratio of quality output to scheduled output adjusted for output losses not attributable to the machine

system at a constant set performance at the level of the nominal performance of the considered machine

system

Note 1 to entry: Corresponds to the previous key figure “technical availability”.

Note 2 to entry: Due to its definition, the technical efficiency is always ≤ 1.
3.1.13.2.4
delivery efficiency
technical delivery efficiency

ratio of the quality output to the agreed output adjusted for output losses not attributable to the machine

system

Note 1 to entry: Corresponds to the key figure “delivery efficiency” according to DIN 8782:1984–05 (see

Bibliography [1]).

Note 2 to entry: The manufactured output can be higher than the agreed output. As a result the delivery efficiency

can be > 1.
3.1.13.2.5
technical mean time to repair
MTTR

mean period of a down time of the machine system due to system related disruptions during the

operating time

Note 1 to entry: Key figure for the evaluation of the system stability based on empirical data.

Note 2 to entry: The determination of a safe mean value for MTTR is not possible within an implementable

acceptance period.
3.1.13.2.6
technical mean time between failures
MTBF

mean time elapsed between down times of the machine system due to system related disruptions during

the operating time
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Note 1 to entry: Key figure for the evaluation of the system stability based on empirical data.

Note 2 to entry: The determination of a safe mean value for MTBF is not possible within an implementable

acceptance period.
3.2 Symbols
Commonly used
Rule for unit, output
Term
Symbol calculation designation or
(en)
(if applicable) formats (if
applicable)
Theoretically available
d; h; min
time
Idle time d; h; min
t t = t – t
Machine working time d; h; min
W W T I
Scheduled down time d; h; min
t t = t – t
Operating time d; h; min
O O W D
Unplanned down time d; h; min
System related
d; h; min
unplanned down time
Unplanned down time
d; h; min
not related to system
t t = t – t
Running time d; h; min
R R O F
t t = t (q / q )
Scrap time d; h; min
LQ LQ O LQ O
t t = t – t – t
Performance loss time d; h; min
LP LP R Q LQ
t t = (q / q ) ⋅ t
Quality time d; h; min
Q Q Q O O
t = t + t + t
L F LP LQ
Loss time d; h; min
= t + t
LS LE
Loss time caused by
d; h; min
system
Loss time not caused
by machine system d; h; min
system
unit
Scheduled output hl, l
t, kg
unit
Agreed output hl, l
t, kg
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Commonly used
Rule for unit, output
Term
Symbol calculation designation or
(en)
(if applicable) formats (if
applicable)
unit
Manufactured output hl, l
t, kg
unit
q q = q – q
Quality output hl, l
Q Q M LQ
t, kg
q = q – q
L O Q
unit
q = q + q
Output losses hl, l
L LS LE
t, kg
= q + q
LP LQ
unit
Scrap hl, l
t, kg
unit
q q = q – q
Performance losses hl, l
LP LP O M
t, kg
unit
Output losses caused
q q = q – q
hl, l
LS LS L LE
by machine system
t, kg
unit
Output losses not
q q = q – q
caused by machine hl, l
LE LE L LS
system
t, kg
unit/
min.
p Performance
l/min.
kg/min.
unit/
min.
Nominal performance
l/min.
kg/min.
unit/
min.
Set performance
l/min.
kg/min.
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Commonly used
Rule for unit, output
Term
Symbol calculation designation or
(en)
(if applicable) formats (if
applicable)
unit/
min.
p p = q / t
Quality performance
Q Q Q O
l/min.
kg/min.
unit/
min.
Technical quality
p p = q / (t – t )
QS QS Q O LE
performance l/min.
kg/min.
Q = q / (q + q )
Q Q LQ
= q / q
Q Quality factor
Q M
= t / (t + t )
Q Q LQ
R = t / t
R Running time factor
R O
Technical availability
R R = t / (t – t )
S S R O FE Technical running
time factor
P = q / q
M O
P Performance factor
= (t + t ) / t
Q LQ O
A = t / t
A Availability
O W
L = t / t
L Loading factor
W T
OEE = t / t
Q W Overall Equipment
OEE
Effectiveness
= Q ⋅ P ⋅ A
E = q / q = Q ⋅ P,
Q O
where
E Efficiency
q = p ⋅ t and
O n O
p ≤ p
s n
E = q / (q – q ),
S Q O LE
where
Technical efficiency
q = p ⋅ t and
O n O
p ≤ p
s n
Delivery efficiency
D = q / (q –
S Q OA
S Technical delivery
q )
efficiency
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Commonly used
Rule for unit, output
Term
Symbol calculation designation or
(en)
(if applicable) formats (if
applicable)
MTTR = t / f
f: total number of the
recorded down
MTTR Mean time to repair
times of the machine
system due to
disruptions
MTTR = t / f
S FS S
where
f : total number of
Technical mean time
MTTR the recorded down
to repair
times of the machine
system due to
system related
disruptions
MTBF = t / f
where
f: total number of the
Mean time between
MTBF
recorded down
failures
times of the machine
system due to
disruptions
MTBF = t / f
S R S
where
f : total number of
Technical mean time
MTBF the recorded down
between failures
times of the machine
system due to
system related
disruptions

NOTE The abbreviation ”d” stands for the English word “day” and designates full days.

4 Key figures for describing the operating behaviour of machine systems
4.1 General

Key figures characterize the use of the machine system. The key figures given here are appropriate for

describing the operating behaviour of the machine system during the operating time when used as

intended. The key figures are established on the basis of time and output losses that have been

determined empirically or in simulations. This document differentiates between general key figures and

technical key figures. General key figures describe the operating behaviour without having to distinguish,

when establishing loss outputs or loss times, whether their causes lie in the machine system itself or

outside of the considered machine system, i.e. external to the machine system. In contrast to this, output

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losses and loss times caused external to the machine system are not taken into consideration for technical

key figures. Thus, to establish technical key figures it is necessary that when determining output losses

and loss times their causes are also clarified. In practice this involves additional effort as, for instance,

displayed disruptions of the machine system can be caused by technical disruptions of upstream or

downstream machine systems, by operating errors or by the flawed quality of the processing materials.

4.2 Calculation bases

For the calculation of the general key figures and the technical key figures the rules for calculation

presented in 3.2 as well as the time model given in Annex A and the output model given in Annex B shall

be used.
4.3 General key figures for describing the operating behaviour

To describe the operating behaviour of machine systems at least the following general key figures shall

be dete
...