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
• Completion Date: 02-Oct-2018

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/TR 22400-10:2018(E)
©
ISO 2018

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ISO/TR 22400-10:2018(E)

COPYRIGHT PROTECTED DOCUMENT
© ISO 2018
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ISO/TR 22400-10:2018(E)

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
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ISO/TR 22400-10:2018(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
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ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
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expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso
.org/iso/foreword .html.
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
complete listing of these bodies can be found at www .iso .org/members .html.

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ISO/TR 22400-10:2018(E)

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.
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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
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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;
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— 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
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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 %
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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 + 222 kWh + = 444,47 kWh
3 3 3 3
6,6 m × 0,102 8 kWh/m + 0,66 m × 10 kWh/m + 6,6 kWh
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 330 min/540 min = 61,11 %
Setup ratio = AUST/AUPT
= 120 min/450 min = 26,67 %
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Table 2 (continued)
Technical = APT/(APT + ADET)
efficiency
= 330 min/(330 min + 90 min) = 78,57 %
Allocation = AUBT/PBT
efficiency
= 540 min/900 min = 60,00 %
Availability = APT/PBT
= 330 min/900 min = 36,67 %
Effectiveness = Effectiveness + Effectiveness
POS 1/2 POS 2/2
 PRI × PQ + PRI × PQ )/APT
POS 1/2 POS 1/2 POS 2/2 POS 2/2
 (0,3 min/Pcs × 450 Pcs + 30 min/Pcs × 6 Pcs)/330 min = 95,45 %
Quality ratio = (GQ + GQ )/(PQ + PQ )
POS 1/2 POS 2/2 POS 1/2 POS 2/2
 (410 Pcs + 4 Pcs)/(450 Pcs + 6 Pcs) = 90,79 %
OEE = Availability × Effectiveness × Quality ratio
= 36,67 % × 95,46 % × 90,79 % = 31,78 %
NEE = AUPT/PBT × Effectiveness × Quality ratio
= 450 min/900 min × 95,46 % × 90,79 % = 43,33 %
Scrap ratio = SQ/PQ
= 32 Pcs/456 Pcs = 7,02 %
Rework ratio = RQ/PQ
= 10 Pcs/456 Pcs = 2,19 %
Actual to planned = SQ/PSQ
scrap ratio
= 32 Pcs/24 Pcs = 133,33 %
MTBF = (AUST + APT + TTR)/(Number (FE) +1)
= (120 min + 330 min + 30 min)/(1 +1) = 240 min
MTTF = (AUST + APT)/(Number (FE) +1)
= (120 min + 330 min)/(1 +1) = 225 min
MTTR = TTR/(Number (FE) +1)
= 30 min/(1 +1) = 15 min
Direct energy = (PDEI × PQ + PDEI × PQ )/ADEC
POS 1/2 POS 1/2 POS 2/2 POS 2/2
consumption
effectiveness
= (0,94 kWh/Pcs × 450 Pcs + 2,10 kWh/Pcs × 6 Pcs)/444,47 kWh = 98,00 %
Direct net energy = (PDEI × GQ + PDEI × GQ )/ADEC
POS 1/2 POS ½ POS 2/2 POS 2/2
consumption
effectiveness
= (0,94 kWh/Pcs × 410 Pcs + 2,10 kWh/Pcs × 4 Pcs)/444,47 kWh = 88,60 %
Direct energy = ADEC/PQ
efficiency
= 444,47 kWh/456 Pcs = 0,975 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 444,47 kWh/414 Pcs = 1,074 kWh/
Pcs
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4.3 KPIs for production orders and production order sequences
From the production order scope the following KPIs can be determined based on the work unit logs:
— Utilization efficiency;
— Setup ratio;
— Technical efficiency;
— Allocation ratio (Production order related);
— Throughput rate (Production order related);
— Effectiveness;
— Production process ratio (Production order related);
— Quality ratio;
— Scrap ratio (Production order related);
— Rework ratio (Production order related);
— Actual to planned scrap ratio (Production order related);
— Fall off ratio (Production order related);
— First pass yield (Production order related);
— Direct energy consumption effectiveness;
— Direct net energy consumption effectiveness;
— Direct energy efficiency;
— Direct net energy efficiency.
Corresponding to “work unit scope” the required basics for the production order or production order
sequence (planned time, actual time and logistical sizes) are determined by using the following table.
Based on these determinations the KPIs will be calculated by considering the event notifications and
messages from the work unit log.
The First Pass Yield (FPY) is described by the relation of Good Quantity [GQ first evaluation] (Good Part
[GP]) to the Produced Quantity [PQ] within the evaluation period – related to the first test run for each
test piece. A completed reworking the FPY cannot be influenced in the second test run, as opposed to
Quality ratio that increases with every successful "verification".
To relate the KPI for each piece it requires a process-related "Serialized/unique-based" flow of products
in which only the first test run of the product is used for the evaluation. Reapplication of testing of a
product is no longer part of the calculation of a FPY, but improves the quality ratio. For the calculation
of the FPY no differentiation takes place for "failed parts" in rework or scrap made by the FPY. If the
piece identification is not possible, then the production order-related Good Quantity [GQ last operation]
the Good Quantity [GQ first test] be equated as Good Parts [GP].
The calculation example given in Tables 3 to 6 is based on the work unit log of work unit W1 and W2.
The quality indicators of the work unit W1 and W2 are determined for the evaluation period of the
calendar day.
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Table 3 — POS 1/1 on work unit 1 time period [06:00 - 11:00]
Determination of basics
APT = [06:30 − 07:00] + [07:30 − 08:00] + = 150 min
[08:30 − 09:00] + [09:30 − 10:30]
AUST = [06:00 − 06:30] + [10:30 − 11:00] = 60 min
ADET = [08:00 − 08:30] + [07:00 − 07:30] + [09:00 − 09:30] = 90 min
TTR = [07:00 − 07:30] + [09:00 − 09:30] = 60 min
PDOT = = 0 min
AUPT = APT + AUST
= 150 min + 60 min = 210 min
AUBT = APT + AUST + ADET
= 150 min + 60 min + 90 min = 300 min
PQ = PQ
POS 1/1
= 500 Pcs = 500 Pcs
GQ = GQ
POS 1/1
= 450 Pcs = 450 Pcs
RQ = RQ
POS 1/1
= 10 Pcs = 10 Pcs
SQ = SQ
POS 1/1
= 40 Pcs = 40 Pcs
PEDI = 0,42 kWh = 0,42 kWh
3 3 3 3
ADEC = 115 m × 0,102 8 kWh/m + 10,5 m × 10 kWh/m + 120 kWh = 236,82 kWh
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 150 min/300 min = 50,00 %
Setup ratio = AUST/AUPT
= 60 min/210 min = 28,57 %
Technical efficiency = APT/(APT + ADET)
= 150 min/(150 min + 90 min) = 62,50 %
Effectiveness = PRI × PQ/APT
 0,3 Pcs/min × 500 Pcs/150 min = 100,00 %
Quality ratio = GQ/PQ
 450 Pcs/500 Pcs = 90,00 %
Direct energy = PDEI × PQ/ADEC
consumption
effectiveness
= 0,42 kWh/Pcs × 500 Pcs/236,82 kWh = 88,67 %
Direct net energy = PDEI × GQ/ADEC
consumption
effectiveness
= 0,42 kWh/Pcs × 450 Pcs/236,82 kWh = 79,81 %
Direct energy = ADEC/PQ
efficiency
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Table 3 (continued)
= 236,82 kWh/500 Pcs = 0,474 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 236,82 kWh/450 Pcs = 0,526 kWh/
Pcs
Table 4 — POS 2/1 on work unit 1 time period [14:30 - 21:00]
Determination of basics
APT = [15:00 − 17:30] + [18:00 − 19:00] + [20:00 − 20:30] = 240 min
AUST = [14:30 − 15:00] + [20:30 − 21:00] = 60 min
ADET = [19:00 − 19:30] + [19:30 − 20:00] = 60 min
TTR = [19:30 − 20:00] = 30 min
PDOT = [17:30 − 18:00] = 30 min
AUPT = APT + AUST
= 240 min + 60 min = 300 min
AUBT = APT + AUST + ADET
= 240 min + 60 min + 60 min = 360 min
PQ = PQ
POS 2/1
= 8 Pcs = 8 Pcs
GQ = GQ
POS 2/1
= 6 Pcs = 6 Pcs
RQ = RQ
POS 2/1
= 0 Pcs = 0 Pcs
SQ = SQ
POS 2/1
= 2 Pcs = 2 Pcs
PEDI = 1,05 kWh = 1,05 kWh
3 3 3 3
ADEC = 4,5 m × 0,102 8 kWh/m + 0,45 m × 10 kWh/m + 4,5 kWh = 9,46 kWh
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 240 min/360 min = 66,67 %
Setup ratio = AUST/AUPT
= 60 min/300 min = 20,00 %
Technical = APT/(APT + ADET)
efficiency
= 240 min/(240 min + 60 min) = 80,00 %
Effectiveness = PRI × PQ/APT
 30 Pcs/min × 8 Pcs/240 min = 100,00 %
Quality ratio = GQ/PQ
 6 Pcs/8 Pcs = 75,00 %
Direct energy = PDEI × PQ/ADEC
consumption
effectiveness
= 1,05 kWh/Pcs × 8 Pcs/9,46 kWh = 88,79 %
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Table 4 (continued)
Direct net energy = PDEI × GQ/ADEC
consumption
effectiveness
= 1,05 kWh/Pcs × 6 Pcs/9,46 kWh = 66,60 %
Direct energy = ADEC/PQ
efficiency
= 9,46 kWh/8 Pcs = 1,183 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 9,46 kWh/6 Pcs = 1,577 kWh/
Pcs
Table 5 — POS 1/2 on work unit 2 time period [06:00 - 17:00]
Determination of basics
APT = [12:00 − 12:30] + [13:00 − 14:00] + = 150 min
[14:30 − 15:00] + [16:00 − 16:30]
AUST = [11:30 − 12:00] + [16:30 − 17:00] = 60 min
ADET = [12:30 − 13:00] + [15:30 − 16:00] + [15:00 − 15:30] = 90 min
TTR = [15:00 − 15:30] = 30 min
PDOT = [14:00 − 14:30] = 30 min
AUPT = APT + AUST
= 150 min + 60 min = 210 min
AUBT = APT + AUST + ADET
= 150 min + 60 min + 90 min = 300 min
PQ = PQ
POS 1/2
= 450 Pcs = 450 Pcs
GQ = GQ
POS 1/2
= 410 Pcs = 410 Pcs
RQ = RQ
POS 1/2
= 10 Pcs = 10 Pcs
SQ = SQ
POS 1/2
= 30 Pcs = 30 Pcs
PEDI = 0,94 kWh = 0,94 kWh
3 3 3 3
ADEC = 210 m × 0,102 8 kWh/m + 18,7 m × 10 kWh/m + 222 kWh = 430,59 kWh
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 150 min/300 min = 50,00 %
Setup ratio = AUST/AUPT
= 60 min/210 min = 28,57 %
Technical = APT/(APT + ADET)
efficiency
= 150 min/(150 min + 90 min) = 62,50 %
Effectiveness = PRI × PQ/APT
 0,3 Pcs/min × 450 Pcs/150 min 90,00 %
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Table 5 (continued)
Quality ratio = GQ/PQ
 410 Pcs/450 Pcs = 91,11 %
Direct energy = PDEI × PQ/ADEC
consumption
effectiveness
= 0,94 kWh/Pcs × 450 Pcs/430,59 kWh = 98,24 %
Direct net energy = PDEI × GQ/ADEC
consumption
effectiveness
= 0,94 kWh/Pcs × 410 Pcs/430,59 kWh = 89,50 %
Direct energy = ADEC/PQ
efficiency
= 430,59 kWh/450 Pcs = 0,957 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 430,59 kWh/410 Pcs = 1,050 kWh/
Pcs
Table 6 — POS 2/2 on Work unit 2 time period [17:30 - 22:00]
Determination of basics
APT = [18:00 − 19:30] + [20:00 − 21:30] = 180 min
AUST = [17:30 − 18:00] + [21:30 − 22:00] = 60 min
ADET = = 0 min
TTR = = 0 min
PDOT = [19:30 - 20:00] = 30 min
AUPT = APT + AUST
= 180 min + 60 min = 240 min
AUBT = APT + AUST + ADET
= 180 min + 60 min + 0 min = 240 min
PQ = PQ
POS 2/2
= 6 Pcs = 6 Pcs
GQ = GQ
POS 2/2
= 4 Pcs = 4 Pcs
RQ = RQ
POS 2/2
= 0 Pcs = 0 Pcs
SQ = SQ
POS 2/2
= 2 Pcs = 2 Pcs
PEDI = 2,10 kWh = 2,10 kWh
3 3 3 3
ADEC = 6,6 m × 0,102 8 kWh/m + 0,66 m × 10 kWh/m + 6,6 kWh = 13,88 kWh
Calculation of KPIs
Utilization = APT/AUBT
efficiency
= 180 min/240 min = 75,00 %
Setup ratio = AUST/AUPT
= 60 min/240 min = 25,00 %
© ISO 2018 – All rights reserved 11

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ISO/TR 22400-10:2018(E)

Table 6 (continued)
Technical = APT/(APT + ADET)
efficiency
= 180 min/(180 min + 0 min) = 100,00 %
Effectiveness = PRI × PQ/APT
 30 Pcs/min × 6 Pcs/180 min = 100,00 %
Quality ratio = GQ/PQ
 4 Pcs/6 Pcs = 66,67 %
Direct energy = PDEI × PQ/ADEC
consumption
effectiveness
= 2,10 kWh/Pcs × 6 Pcs/13,88 kWh = 90,78 %
Direct net energy = PDEI × GQ/ADEC
consumption
effectiveness
= 2,10 kWh/Pcs × 4 Pcs/13,88 kWh = 60,52 %
Direct energy = ADEC/PQ
efficiency
= 13,88 kWh/6 Pcs = 2,313 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 13,88 kWh/4 Pcs = 3,470 kWh/
Pcs
Based on the data of the single production order sequence or the work unit log the order-related actual
times and KPIs can determined. This is shown in Tables 7 and 8.
Table 7 — Production order-related actual times and KPIs PO1 in conjunction with POS1/1
and POS1/2
Determination of basics
AOET = Endtime − Starttime
POSPO1/2 POSPO1/1
= [17:00] – [06:00] = 660 min
GQ GQ
POS 1/2
= 410 Pcs = 410 Pcs
SQ SQ + SQ
POS 1/1 POS 1/2
= 40 Pcs+ 30 Pcs = 70 Pcs
RQ RQ + RQ
POS 1/1 POS 1/2
= 10 Pcs + 10 Pcs = 20 Pcs
PQ PQ
POS 1/1
= 500 Pcs = 500 Pcs
PSQ Planned scrap quantity in % × PQ +
POS 1/1
Planned scrap quantity in % × PQ
POS 1/2
= 5 % × 500 Pcs + 5 % × 450 Pcs = 48 Pcs
GP Complies with GQ because there is no serialization to identify a
first pass
 410 Pcs = 410 Pcs
IP Complies with PQ because there is no serialization to identify a
first pass
 500 Pcs = 500 Pcs
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ISO/TR 22400-10:2018(E)

Table 7 (continued)
ADEC ADEC ADEC
POS 1/1 + POS 1/2
3 3 3 3
= 115 m × 0,102 8 kWh/m + 10,5 m × 10 kWh/m + 120 kWh + = 667,41 kWh
3 3 3 3
210 m × 0,102 8 kWh/m + 18,7 m × 10 kWh/m + 222 kWh
PEDI = 0,42 kWh = 0,42 kWh
POS 1/1
PEDI = 0,94 kWh = 0,94 kWh
POS 1/2
Calculation of KPIs
Allocation ratio = (AUBT + AUBT )/AOET
POSPO1/1 POSPO1/2
= 600 min/660 min = 90,91 %
Throughput rate = PQ/AOET
= 450 Pcs/660 min = 0,71 Pcs/min
Production = (APT + APT )/AOET
POSPO1/1 POSPO1/2
process ratio
= (150 min + 150 min)/660 min = 47,62 %
Quality ratio = GQ/PQ
= 410 Pcs/500 Pcs = 82,00 %
Scrap ratio = SQ/PQ
= 70 Pcs/500 Pcs = 14,00 %
Rework ratio = RQ/PQ
= 20 Pcs/500 Pcs = 4,00 %
Actual to planned = SQ/PSQ
scrap ratio
= 70 Pcs/48 Pcs = 145,83 %
Fall off ratio = (PQ – GQ)/PQ
= (500 – 410 Pcs)/500 Pcs = 18,00 %
First pass yield = GP/IP
= 410 Pcs/500 Pcs = 82,00 %
Direct energy = (PDEI × PQ + PDEI × PQ )/ADEC
POS 1/1 POS 1/1 POS 1/2 POS 1/2
consumption
effectiveness
= (0,42 kWh/Pcs × 500 Pcs + 0,94 kWh/Pcs × 450 Pcs)/667,41 kWh = 94,84 %
Direct net energy = PDEI GQ PDEI GQ ) /ADEC
POS 1/1 × POS 1/1 + POS 1/2 × POS 1/2
consumption
effectiveness
= (0,42 kWh/Pcs × 450 Pcs + 0,94 kWh/Pcs × 410 Pcs)/667,41 kWh = 86,06 %
Direct energy = ADEC/PQ
efficiency
= 667,41 kWh/450 Pcs = 1,483 kWh/
Pcs
Direct net energy = ADEC/GQ
efficiency
= 667,41 kWh/410 Pcs = 1,628 kWh/
Pcs
© ISO 2018 – All rights reserved 13

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ISO/TR 22400-10:2018(E)

Table 8 — Production order-related actual times and KPIs PO2 in conjunction with POS2/1
and POS2/2
Determination of basics
AOET = Endtime – Starttime
POS 2/2 POS 2/1
= [22:00] – [14:30] = 450 min
GQ GQ
POS 2/2
= 4 Pcs = 4 Pcs
SQ SQ + SQ
POS 2/1 POS 2/2
= 2 Pcs + 2 Pcs = 4 Pcs
RQ RQ + RQ
POS 2/1 POS 2/2
= 0 Pcs = 0 Pcs
PQ PQ
POS 2/1
= 8 Pcs = 8 Pcs
PSQ Planned scrap quantity in % × PQ
POS 2/1 +
Planned scrap quantity in % × PQ
POS 2/2
= 25 % × 8 Pcs + 25 % × 6 Pcs = 4 Pcs
IP Number of pieces being tested on both production sequences (serial
number S01 bis S08)
= 8 Pcs = 8 Pcs
GP Number of pieces that are good on both production sequences in the
first round without reworking (serial number S01)
= 1 Pcs = 1 Pcs
IP Number of pieces that have been tested
POS 2/1
(serial number S01 to S08)
= 8 Pcs = 8 Pcs
GP Number of pieces being good in the first round
POS 2/1
(serial number S01, S05, S07, S08)
= 4 Pcs = 4 Pcs
IP Number of pieces that have been tested
POS 2/2
(serial number S01, S02, S05, S06, S07, S08)
= 6 Pcs = 6 Pcs
GP Number of pieces being good in the first pass
POS 2/2
(serial number S01, S06)
= 2 Pcs = 2 Pcs
ADEC ADEC ADEC
POS 2/1 + POS 2/2
3 3 3 3
= 4,5 m × 0,102 8 kWh/m + 0,45 m × 10 kWh/m + 4,5 kWh + = 23,34 kWh
3 3 3 3
6,6 m × 0,102 8 kWh/m + 0,66 m × 10 kWh/m + 6,6 kWh
PEDI = 1,05 kWh = 1,05 kWh
POS 2/1
PEDI = 2,10 kWh = 2,10 kWh
POS 2/2
Calculation of KPIs
Allocation ratio = (AUBT + AUBT )/AOET
POS 2/1 POS 2/2
= 600 min/450 min = 133,33 %
Throughput rate = PQ/AOET
= 6 Pcs/450 min = 0,01 Pcs/min
Production = (APT + APT )/AOET
POS 2/1 POS 2/2
process ratio
= (240 min + 180 min)/450 min = 93,33 %
14 © ISO 2018 – All rights reserved

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