Introduction
The WatchMen Platform by Novo AI helps manufacturing companies track and improve production efficiency by providing real-time insights into key performance metrics. By integrating with existing Production Data Acquisition Systems (PDA) or Enterprise Resource Planning (ERP) systems, WatchMen enables automated data collection and analysis for better decision-making.
This document outlines the core calculations used within the WatchMen platform to assess quality, availability, performance, energy consumption, and related costs.
Quality
Definition: Quality represents the effectiveness of production output and is set by default to 95% company-wide. However, it can be adjusted per machine or per order when using WatchMen’s Production Data Acquisition (PDA) system or when integrated with an ERP system.
Calculation: When integrated, quality is determined by comparing the actual good units produced to the total produced units, taking into account any defective or waste materials that reduce the overall quality.
Example:
-
Total Produced: 100 units
-
Good Units: 95 units (when this data is not available, planned number of units is considered)
-
Quality = (Good Units / Total Produced) × 100
-
Quality = 95%
This metric helps assess whether production is meeting expected quality standards and highlights discrepancies in output.
Availability
Definition: Availability measures the proportion of total operational time a machine is actively producing compared to the total scheduled time.
Calculation: Availability is determined by dividing the actual production duration by the total available time, which includes both active and idle time.
Example:
-
Production Duration: 3 hours
-
Preparation Duration: 1 hour
-
Idle Duration: 1 hour
-
Off Duration: 2 hours
-
Total Duration (production + preparation + idle + off): 7 hours
-
Availability = (Production Duration / Total Duration) × 100
-
Availability = 42.85%
This helps identify how effectively machines are utilized and highlights potential bottlenecks in production.
Performance
Definition: Performance evaluates how efficiently a machine runs compared to its operational time, including preparation time.
Calculation: Performance is calculated by assessing the time spent in actual production and preparation relative to the machine’s total available running time.
Example:
-
Production Duration: 3 hours
-
Preparation Duration: 1 hour
-
Idle Duration: 1 hour
-
Off Duration: 2 hours
-
Machine Effective Time (production + preparation): 4 hours
-
Machine On Time (production + preparation + idle): 5 hours
-
Performance = (Machine Effective Time / Machine On Time) × 100
-
Performance = 80%
This metric provides insights into machine speed and efficiency during operations.
Overall Equipment Effectiveness (OEE)
Definition: OEE is a key metric used to measure manufacturing productivity by combining availability, performance, and quality into a single percentage.
Calculation: OEE is calculated as the product of availability, performance, and quality.
Example:
-
Availability: 42.85%
-
Performance: 80%
-
Quality: 95%
-
OEE = (Availability × Performance × Quality) / 100
-
OEE = 32.56%
This metric provides a comprehensive view of overall manufacturing efficiency and highlights areas for improvement.
Energy Consumption
Definition: Energy consumption measures the total energy used during machine operation, considering both idle and production phases.
Calculation: Energy consumption is determined by the sum of:
-
Energy used during idle time.
-
Energy used during active production and preparation.
The energy consumption depends on:
-
Machine energy factor: Accounts for additional components such as air filters, pumps, and motors.
-
Machine intensity factor: Represents machine speed-to-energy consumption correlation.
-
Energy rating: Defines the machine’s watt consumption per hour.
Example:
-
Idle Duration: 2 hours
-
Production + Preparation Duration: 4 hours
-
Machine Energy Factor: 0.35
-
Machine Intensity Factor: varies
-
Watt Consumption Rating: 500W
Total energy consumption is derived by weighting idle and active periods appropriately.
Energy Wastage
Definition: Energy wastage represents the portion of energy consumed while the machine is idle, contributing to unnecessary costs.
Calculation: Energy wastage is calculated based on the machine’s idle duration, energy rating, and machine energy factor.
Example:
-
Idle Duration: 2 hours
-
Machine Energy Factor: 0.35
-
Watt Consumption Rating: 500W
Energy wastage is derived by multiplying these values, indicating unnecessary power usage.
Energy Consumption Costs
Definition: Energy consumption costs estimate the total cost incurred for running the machines.
Calculation: Energy cost is determined by multiplying total energy consumption by the energy price per unit.
Example:
-
Total Energy Consumption: 20 kWh
-
Energy Price: €0.15 per kWh
-
Cost = €3.00
This allows manufacturers to assess and optimize energy expenditure.
Energy Wastage Costs
Definition: Energy wastage costs represent the financial impact of idle energy consumption.
Calculation: Energy wastage costs are computed by multiplying energy wastage by the energy price per unit.
Example:
-
Energy Wastage: 5 kWh
-
Energy Price: €0.15 per kWh
-
Cost = €0.75
Minimizing energy wastage leads to cost reductions and improved sustainability.