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KPIs

Definition​

In the previous section, we have seen what Overall Equipment Effectiveness is and the three key metrics needed to calculate it, namely Availability, Performance and Quality. Aside from these KPIs, there are a lot more that you can display on your dashboards. This section will review each one of them briefly.

Availability KPIs​

Uptime​

This is the time a machine has spent working.
For example, in a 8-hour shift, if a machine is producing during 6 hours, the uptime will be 6 hours.

Use ratio​

Given a timespan (e.g.: a shift), the use ratio is the ratio between the uptime during the timespan and the timespan itself.
For example, in a 8-hour shift, if the machine has been working for a total of 6 hours, its use ratio for the shift is 6/8 = 75%.

Planned production time​

The planned production time is the total time that was initially scheduled for production. Therefore, it is the sum of the uptime and the unplanned downtimes.

Downtimes​

Downtimes can be broken down into a few categories. As you will see in the stop causes section, you can categorize your stop causes into the following categories: Planned, Failure, Idle, Changeover and Minor. As a result, you can display the downtime that is specific to each one of these categories.

Planned downtime​

This is the downtime due to "planned" stop causes, a lunch break for instance.

Unplanned downtime​

This is the downtime due to unplanned stop causes, a broken tool for instance.
This downtime includes the stop causes: Failure, Idle, Changeover and Minor.

Failure downtime​

This is the downtime due to machine failure.

Changeover downtime​

This is the downtime due to changeover and setup.

Idle downtime​

This is the downtime due to the machine idling. The machine is ready to go, but it cannot produce because of external reasons, such as lack of material.

Minor stop downtime​

This is the downtime due to minor stops.

Performance and Quality KPIs​

Input part count​

This is the number of parts that entered the machine.

Output part count​

This is the number of parts that exited the machine.

Good part count​

This is the number of parts that exited the machine and have not been rejected.

Defect count​

This is the number of parts that exited the machine and have been rejected for quality reasons.

Production goal​

This is the number of input parts that is expected to be produced during the planned production time over a given timespan.
For example, during a shift, if the planned production time is 6 hours and the unit completion time is 10 minutes, the production goal is 36 parts.

Hourly input part rate​

This is the average number of input parts per hour for the time the machine has been running (uptime).
For example, during a shift, if the machine has been running for a total of 6 hours and 30 parts entered the machine (input parts), the hourly input part rate is 30/6 = 5 input parts per hour.

Hourly output part rate​

This is the average number of output parts per hour for the time the machine has been running (uptime).
For example, during a shift, if the machine has been running for a total of 6 hours and 30 parts exited the machine (output parts), the hourly output part rate is 30/6 = 5 output parts per hour.

Hourly good output part rate​

This is the average number of output parts per hour for the time the machine has been running (uptime).
For example, during a shift, if the machine has been running for a total of 6 hours and 30 parts exited the machine (output parts), but 12 of those parts were rejected (defects), the hourly output part rate is (30-12)/6 = 3 good output parts per hour.

Hourly defect rate​

This is the average number of defects per hour for the time the machine has been running (uptime).
For example, during a shift, if the machine has been running for a total of 6 hours and 30 parts exited the machine (output parts), but 12 of those parts were rejected (defects), the hourly output part rate is 12/6 = 2 defects per hour.

Hourly ideal rate​

This is the average number of expected input parts per hour for the time the machine has been running (uptime).
For example, during a shift, if the machine has been running for a total of 6 hours and the unit completion time is 10 minutes, the hourly ideal rate is (1 hour/10 minutes) = 6 parts per hour.

Production rate​

This is the ratio of the hourly input rate to the hourly ideal rate. The more the two numbers match, the more you are producing at an ideal rate when the machine is running.

Production ratio​

This is the ratio of the input count to the expected input count. It is very similar to the production rate, but expressed in absolute values instead of hourly rates.

Planned production ratio​

This is the ratio of the input count to the expected input count, but during the planned production time, which differentiates if from the production ratio that uses the uptime instead.

Unit completion time​

This is the ideal production time for one unit of the parts that are being produced. It is a constant that is defined for every SKU number of your machine.