ISO/TR 22400-10:2018

Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 10: Operational sequence description of data acquisition

This document contains descriptions for the practical use for applying formulae as specified in ISO 22400-2 for key performance indicators for production control and monitoring. This document is intended to be applied in conjunction with the content of ISO 22400-2.

Systèmes d'automatisation et intégration — Indicateurs de la performance clé pour le management des opérations de fabrication — Partie 10: Description de l’acquisition des données relatives aux séquences opérationnelles

General Information

• Status: Published
• Publication Date: 01-Oct-2018
• ICS: 25.040.01 - Industrial automation systems in general
• Technical Committee: ISO/TC 184/SC 5 - Interoperability, integration, and architectures for enterprise systems and automation applications
• Drafting Committee: ISO/TC 184/SC 5/WG 9 - Key performance indicators for manufacturing operations management
• Current Stage: 6060 - International Standard published
• Start Date: 02-Oct-2018
• Completion Date: 19-Apr-2025

Standards Content (Sample)

TECHNICAL ISO/TR
REPORT 22400-10
First edition
2018-10
Automation systems and
integration — Key performance
indicators (KPIs) for manufacturing
operations management —
Part 10:
Operational sequence description of
data acquisition
Systèmes d'automatisation et intégration — Indicateurs de
la performance clé pour le management des opérations de
fabrication —
Partie 10: Description de l’acquisition des données relatives aux
séquences opérationnelles
Reference number
©
ISO 2018
© ISO 2018
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
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ii © ISO 2018 – All rights reserved

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 KPI calculation examples . 2
4.1 Example setup . 2
4.2 KPIs for work unit . 2
4.3 KPIs for production orders and production order sequences . 7
4.4 KPIs for worker.15
Annex A (informative) Example: Work unit data recording for KPI calculation .19
Foreword
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This document was prepared by Technical Committee ISO/TC 184, Automation systems and integration,
Subcommittee SC 5, Interoperability, integration, and architectures for enterprise systems and automation
applications.
A list of all parts in the ISO 22400 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
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iv © ISO 2018 – All rights reserved

Introduction
This document describes the procedure for the determination of key performance indicators (KPIs) by
means of examples. The KPIs that are used are given in ISO 22400-2.
TECHNICAL REPORT ISO/TR 22400-10:2018(E)
Automation systems and integration — Key performance
indicators (KPIs) for manufacturing operations
management —
Part 10:
Operational sequence description of data acquisition
1 Scope
This document contains descriptions for the practical use for applying formulae as specified in
ISO 22400-2 for key performance indicators for production control and monitoring. This document is
intended to be applied in conjunction with the content of ISO 22400-2.
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.
ISO 22400-2:2014, Automation systems and integration — Key performance indicators (KPIs) for
manufacturing operations management — Part 2: Definitions and descriptions
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 22400-2 and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
3.1
planned shut down time
PSDT
time in which the work unit is planned to be out of operation
Note 1 to entry: Corresponds to “no production” as defined in ISO 22400-2.
3.2
planned down time
PDOT
time, included in the planned operation time, in which the work unit is planned for no operations within
the operation time period
Note 1 to entry: ISO 22400-2:2014, Figure 3, gives a detailed overview of the used time lines for work units as
used for the ISO 22400 series.
3.3
work unit log
data recording of work unit events along with their time stamps
4 KPI calculation examples
4.1 Example setup
KPIs are calculated for different scopes including work unit and production orders. The KPIs are
determined from the work unit log.
The example given in Tables 1 and 2 consists of two work units (W1 and W2) within a time period of one
calendar day. Two production orders (PO1 and PO2) are executed in this production area within this
calendar day. A work unit log for each work unit is produced. Based on the data in the work unit logs,
KPIs can be calculated. The scope of the KPI can be the work unit, the production order, the worker etc.
Each Production Order (PO) is composed of two Production Order Sequences (POS):
— PO1: POS 1/1 followed by POS 1/2;
— PO2: POS 2/1 followed by POS 2/2.
In the example POS x/1 is always executed on work unit W1.
In the example POS x/2 is always executed on work unit W2.
The calculation of the KPIs takes place in two steps.
a) Determine KPI elements.
The KPI elements can be determined based on the work unit logs
b) Calculate KPIs.
The KPIs can be calculated based on the KPI elements.
The details are defined in “comments on the work unit logs”. The examples use “pieces” (Pcs) as item
unit, however, any kind of item unit can be used.
4.2 KPIs for work unit
From work unit scope the following KPIs can be determined based on the work unit logs:
— Utilization efficiency;
— Setup ratio;
— Technical efficiency;
— Allocation efficiency;
— Availability;
— Effectiveness;
— Quality ratio;
— Overall equipment effectiveness index (OEE);
— Net equipment effectiveness index (NEE);
— Scrap ratio;
— Rework ratio;
— Actual to planned scrap ratio;
— MTBF;
2 © ISO 2018 – All rights reserved

— MTTF;
— MTTR;
— Direct energy consumption effectiveness;
— Direct net energy consumption effectiveness;
— Direct energy efficiency;
— Direct net energy efficiency.
Table 1 — Log of work unit 1
Determination of basics
APT = [06:30 − 07:00] + [07:30 − 08:00] + [08:30 − 09:00] + = 390 min
[09:30 − 10:30] + [15:00 − 17:30] + [18:00 − 19:00] +
[20:00 − 20:30]
AUST = [06:00 − 06:30] + [10:30 − 11:00] + [14:30 − 15:00] + = 120 min
[20:30 − 21:00]
ADET = [08:00 − 08:30] + [19:00 − 19:30] + [07:00 − 07:30] + = 150 min
[09:00 − 09:30] + [19:30 − 20:00]
TTR = [07:00 − 07:30] + [09:00 − 09:30] + [19:30 − 20:00] = 90 min
PSDT = [00:00 − 06:00] + [22:00 − 24:00] = 480 min
PDOT = [12:00 − 12:30] + [17:30 − 18:00] = 60 min
PBT = 1 440 min – PSDT – PDOT = 900 min
1 440 min – 480 min – 60 min
AUPT = APT + AUST
= 390 min + 120 min = 510 min
AUBT = APT + AUST + ADET =
= 390 min + 120 min + 150 min = 660 min
GQ GQ + GQ
POS 1/1 POS 2/1
= 450 Pcs + 6 Pcs = 456 Pcs
SQ SQ + SQ
POS 1/1 POS 2/1
= 40 Pcs + 2 Pcs = 42 Pcs
RQ RQ + RQ
POS 1/1 POS 2/1
= 10 Pcs + 0 Pcs = 10 Pcs
PQ PQ + PQ
POS 1/1 POS 2/1
= 500 Pcs + 8 Pcs = 508 Pcs
PSQ Planned scrap quantity in % × PQ +
POS 1/1
Planned scrap quantity in % × PQ
POS 2/1
= 5 % × 500 Pcs + 25 % × 8 Pcs = 27 Pcs
PEDI = 0,42 kWh = 0,42 kWh
POS 1/1
PEDI = 1,05 kWh = 1,05 kWh
POS 2/1
ADEC ADEC + ADEC
POS 1/1 POS 2/1
3 3 3 3
= 115 m × 0,102 8 kWh/m + 10,5 m × 10 kWh/m + 120 kWh + = 246,28 kWh
3 3 3 3
4,5 m × 0,102 8 kWh/m + 0,45 m × 10 kWh/m + 4,5 kWh
Table 1 (continued)
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 390 min/660 min = 59,09 %
Setup ratio = AUST/AUPT
= 120 min/510 min = 23,53 %
Technical efficiency = APT/(APT + ADET)
= 390/(390 + 150) = 72,22 %
Allocation efficiency = AUBT/PBT
= 660 min/900 min = 73,33 %
Availability = APT/PBT
= 390 min/900 min = 43,33 %
Effectiveness = Effectiveness + Effectiveness
POS 1/1 POS 2/1
= (PRI × PQ + PRI PQ ) /APT
POS 1/1 POS 1/1 POS 2/1 POS 2/1
(0,3 min/Pcs × 500 Pcs + 30 min/Pcs × 8 Pcs)/390 min = 100,00 %
Quality ratio = (GQ + GQ )/(PQ + PQ )
POS 1/1 POS 2/1 POS 1/1 POS 2/1
= (450 Pcs + 6 Pcs)/(500 Pcs + 8 Pcs) = 89,76 %
OEE = Availability × Effectiveness × Quality ratio
= 43,33 % × 100 % × 89,76 % = 38,89 %
NEE = AUPT/PBT × Effectiveness × Quality ratio
= 510 min/900 min × 100 % × 89,76 % = 50,86 %
Scrap ratio = SQ/PQ
= 42 Pcs/508 Pcs = 8,27 %
Rework ratio = RQ/PQ
= 10 Pcs/508 Pcs = 1,97 %
Actual to planned = SQ/PSQ
scrap ratio
= 42 Pcs/27 Pcs = 155,56 %
MTBF = (AUST + APT + TTR)/(Number(FE) +1)
= (120 min + 390 min + 90 min)/(3 +1) = 150 min
MTTF = (AUST + APT)/(Number(FE) +1)
= (120 min + 390 min)/(3 +1) = 127,5 min
MTTR = TTR/(Number(FE) +1)
= 90 min/(3 +1) = 22,5 min
Direct energy = (PDEI × PQ + PDEI × PQ )/ADEC
POS 1/1 POS 1/1 POS 2/1 POS 2/1
consumption
effectiveness
= (0,42 kWh/Pcs × 500 Pcs + 1,05 kWh/Pcs × 8 Pcs)/246,28 kWh = 88,68 %
Direct net energy = PDEI × GQ + PDEI × GQ )/ADEC
POS 1/1 POS 1/1 POS 2/1 POS 2/1
consumption
effectiveness
= (0,42 kWh/Pcs × 450 Pcs + 1,05 kWh/Pcs × 6 Pcs)/246,28 kWh = 79,30 %
4 © ISO 2018 – All rights reserved

Table 1 (continued)
Direct energy = ADEC/PQ
efficiency
= 246,28 kWh/508 Pcs = 0,485 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 246,28 kWh/456 Pcs = 0,540 kWh/
Pcs
Table 2 — Log of Work unit 2
Determination of basics
APT = [12:00 − 12:30] + [13:00 − 14:00] + [14:30 − 15:00] + = 330 min
[16:00 − 16:30] + [18:00 − 19:30] + [20:00 − 21:30]
AUST = [11:30 − 12:00] + [16:30 − 17:00] + [17:30 − 18:00] + = 120 min
[21:30 − 22:00]
ADET = [12:30 − 13:00] + [15:30 − 16:00] + [15:00 − 15:30] = 90 min
TTR = [15:00 − 15:30] = 30 min
PSDT = [00:00 − 06:00] + [22:00 − 24:00] = 480 min
PDOT = [14:00 − 14:30] + [19:30 − 20:00] = 60 min
PBT = 1 440 min – PDBT – PDOT = 900 min
1 440 min – 480 min – 60 min
AUPT = APT + AUST
= 330 min + 120 min = 450 min
AUBT = APT + AUST + ADET
= 330 min + 120 min + 90 min = 540 min
GQ GQ + GQ
POS 1/2 POS 2/2
= 410 Pcs + 4 Pcs = 414 Pcs
SQ SQ SQ
POS 1/2 + POS 2/2
= 30 Pcs + 2 Pcs = 32 Pcs
RQ RQ + RQ
POS 1/2 POS 2/2
= 10 Pcs + 0 Pcs = 10 Pcs
PQ PQ + PQ
POS 1/2 POS 2/2
= 450 Pcs + 6 Pcs = 456 Pcs
PSQ Planned scrap quantity in % × PQ +
POS 1/2
Planned scrap quantity in % × PQ
POS 2/2
= 5 % × 450 + 25 % × 6 Pcs = 24 Pcs
PEDI = 0,94 kWh = 0,94 kWh
POS 1/2
PEDI = 2,10 kWh = 2,10 kWh
POS 2/2
ADEC ADEC + ADEC
POS 1/2 POS 2/2
3 3 3 3
= 210 m × 0,102 8 kWh/m + 18,7 m × 10 kWh/m + 2
...