Table of Contents

Devices

The NIS in the line

How to implement the NIS in the field

Interfaces

The LED TV (Andon board)

The Andon board interface

The touch panel interface

Advancement of the pieces

Declaring scrap

Tooling

Declaring stop for failure or slowdown

Declaring stop for organizational cause

Production change

The flashback function

In the office

NIS web platform

The main menu

Users

The environment

Non-compliant causes

Downtime causes

Productions

Utilities

Reports

Production line status

Efficiency

Reports

OEE overview

How does it work

NIS User Handbook

Devices

The NIS in the Line

NIS is an acronym that stands for Next Improve System. NIS allows the control and monitoring of production efficiency, both in real time (Andon) and over a certain period (OEE).

How to Implement the NIS in the Field

To implement a NIS system, you need the following devices:

An LED TV (we recommend a size from 40 inches up)

A mini PC

A Touch Panel

A Barcode reader

A PLC

For each production line, there will be a touch panel and an LED TV (The Andon board).
The NIS system

Connected to the touch panel is the barcode reader that will help the operator change the production order and, in case of absence of the PLC, increase the number of pieces produced.
The barcode reader is connected to the touch panel via a USB port, and the touch panel is connected to the system via an ethernet cable.
how to wire a touch panel
The barcode reader

The Mini PC is connected to the LED TV via an HDMI port and is also connected to the system via an ethernet cable.
LED TV and mini PC

The main difference compared to a line without a PLC concerns the signaling mode of the advancement of a piece: the PLC automatically sends a signal when the operator performs the last operation.
Another signal from the PLC indicates if the machine is running or not.
Each PLC can be connected to 4 machines because it is provided with 8 slots.
The PLC

Interfaces

The LED TV (Andon Board)

The Andon board shows different data relating to real-time production.
The Andon Board interface

The Andon Board Interface

At the top of the page, a horizontal bar shows the sequence of stops of any type (programmed stop, stop for maintenance, etc.).
In green, the time the line is running; in red when it is stopped, and in blue when the stop is scheduled.
the sequence of stops

Let's see the meaning of each element:

At the top on the left, there is the «Production Order code» currently ongoing.

At the top on the right, there is the date and time.

Takt-time: is the time that each operator has to carry out its task.

Expected items: it represents the theoretical production.

Produced items: it represents the number of produced products, both goods and scraps.

Remaining batch: the number of pieces that remain to complete the entire lot production.

Non-compliant items: the number of parts not good (scrap items).

OEE: on the right, there is the OEE value expressed as a percentage, referred to the current shift. Single percentages are also specified for availability, speed, and quality.

The Andon board interface

Even the colors of some elements have a specific meaning.
Green background: the background is green when the number of "Expected items" (for the current production) is equal to the number of "Produced items".
Green background

Yellow background: the background is yellow when the number of "Expected items" (for the current production) is greater by one or two items compared to the number of "Produced items".
Yellow background

Red background: the background is red when the number of "Expected items" (for the current production) is greater than the number of "Produced items" by three or more.
Red background

Also, the area "Non-compliant items" has its background color. Now we see the meaning of these colors.

Green background: there were non-scrap items.

Yellow background: there were one or two scrap items.

Red background: there were three or more scrap items.

Non-compliant items background

Also, the box that hosts the percentage of OEE will appear with different colors.

Green: the percentage value is greater than 81%.

Yellow: the percentage value is between 71% and 80%.

Red: the percentage value is between 0 and 70%.

OEE percentage

These percentage values can be customizable line by line, so they may differ from those shown in this guide. Likewise, the individual boxes of "Availability," "Speed," and "Quality" can take on different colors.

The Touch Panel

The Touch Panel Interface

This is the interface of the touch panel.
The red, blue, yellow, and green areas are buttons that allow the operator to access certain functions.
The touch panel interface

The "Scrap items" button provides access to a dialog box containing the datasheet of the loss of quality causes. The operator must specify the appropriate cause.
For more information, see the paragraph "Declaring scrap."
Scrap items

The "Tool changeover time" button starts the setup process.
For more information, see unit "Tooling."
Tooling

The "Failure / Slowdowns" button provides access to a dialog box containing the datasheets of the causes of the stops.
The operator must specify the appropriate cause.
For more information, see unit "Declaring stop for failure or slowdown."
Failure / Slowdowns

The "Organizational" button provides access to some particular stop causes that have to concern organizational factors.
The operator must specify the appropriate cause.
For more information, see unit "Declaring stop for organizational cause."
Organizational

Below the four buttons, you can read the name of the line and the order of production that is processed at that time.
Production order and production line name

At the bottom on the left, there is the "OP button" that allows the operator to change the production order.
For more information, see unit "Production change."
Production order change

At the bottom on the right, there is the "Flashing back" button that allows the operator to switch, to SAP, the quantity of produced units and non-compliant items.
For more information, see unit "Flashback function."
Flashback function

Near the "Flashing back" button, there is the button to refresh the page.
Refresh page

Advancement of the Pieces

Here we'll show how to advance the pieces (with or without a PLC).
Without a PLC
When the operator finishes all the operations, before moving on to the next piece, he/she will indicate the progress of the piece using the barcode reader, scanning the unique item number.
Advancement of the pieces with the barcode reader

With a PLC
The main difference compared to a line without a PLC concerns the signaling mode of the advancement of a piece: it is the PLC that automatically sends a signal when the operator performs the last operation.
Advancement of the pieces with the PLC

The number of pieces will be updated on the Andon board (LED TV), under the heading "Produced items."
The Andon board

Declaring scrap

The following paragraph will show how the operator can declare the scrap items.

Press the red area called «Scrap items»

Scrap items

The operator has to choose from a list of causes

The list of causes

Once the type of defect has been chosen, the operator can define the amount of pieces to be discarded

the amount of pieces to be discarded
A message will inform the operator that the scrap declaration has been successful
Scrap declaration successful

Tooling

The following paragraph will show how the operator can start the tool changeover time.

Press the blue area called «Tool changeover time»

ool changeover time

The system will ask for confirmation of the choice to start the tooling

The system will ask for confirmation

Once the tooling has started, it will start blinking blue/orange for the entire duration.

Blinking

Press the blinking area to end the tooling. The system will ask for confirmation.

The system will ask for confirmation

Declaring stop for failure or slowdwn

The following paragraph will show how the operator can stop the system for failure or slowdown

Press the yellow area called «Failure/slowdowns»

Failure/slowdowns

The operator will have to choose the correct stop cause

Stop causes

The system will ask for confirmation of the choice

Ask for confirmation

Once the stop has started, it will start blinking yellow/orange for the entire duration

Blinking

Press the blinking area to end the stop machine. The system will ask for confirmation

Ask for confirmation

It’s also possible to switch from the stop machine, to tooling while stop is active

Begin tool changeover time

Declaring stop for organizational cause

The following paragraph will show how the operator can stop the system for an organizational cause

Press the green area called «Organizational»

Organizational

The operator will have to choose the correct organizational stop cause

Orgaizational stop causes

The operator will have to confirm the choice

Ask for confirmation

Once the stop has started, it will start blinking yellow/orange for the entire duration

Blinking

Press the blinking area to end the stop machine. The system will ask for confirmation

Ask for confirmation

It’s also possible to switch from the stop machine to tooling while stop is active

Begin tool changeover time

Production change

The following paragraph will show how to change a production

Open the list of workorders and Press on the "OP" button to open the list. That list is sorted by release date in ascending order.

Change production

Choose the workorder from the list. Use the buttons at the bottom to navigate.

Choose the workorder

Press the "Play" button on the desired workorder to start a new production. A confirmation message will be shown.

start a new production

Verify information on the touch panel. The new production will be configured and the information about the selected work order, will be shown on the touch panel.

The new production

The falshback function

The flashback function allows the operator to switch to SAP, quantity of units produced and non-compliant items.

Press the button at the bottom on the right, representing the icon of a lightning

Flashback function

Enter the RUEK code. By default, the system proposes the current production code.

Enter the RUEK code

From this screen the operator can communicate the quantity of units produced up to that time, and the quantity of non compliant items. The operator may also modify:

the quantity of units produced (1)

the amount of non compliant items (2)

he can declare the order completed (3)

finally, the operator must press the "Flashback" button at the bottom right (4)

Flashback data to SAP

This is the screen to change the amount of units produced.

Change the amount of units produced

This is the screen to change the amount of non compliant items.

Change the amount of non compliant items

When the operator presses the "Flashback" button, the system asks for confirmation of the operation

Ask for confirmation

Tracking maintenance

It's possible to track the maintenance during a stop machine.
When the resource has a stop machine running, two additional buttons will be shown.
stop machine running
The operator will press the green one with the wrench icon and then will confirm the choise.
Success / error message will be shown based on the result of the operation.
Now, the green button become grayout (disabled) and the other button with the wrench icon become red: the operator has to press it to end the maintenance.
The running stop machine remains as is until the operator press the yellow blinking button “failure / slowdowns”.

In the office

NIS web platform

The main menu

From the office the user will be able to view, manage and customize the entire NIS system.
All the operations the user can do are listed in the main menu. The menu provides different entries, depending on who is logged.
This is the menu that can see a user with the role of administrator.
The manin manu
The «Environments» section contains some general voices describing users, departments, lines, shifts, cycle time adjustments and scheduled pauses.
Through each single entry the user will be able to make settings and changes related to the context.
We will deepen this topic in the paragraphs «Users» and «The environment».
Environment
The «Causes» section represents the list of possible downtime or non-compliant causes.
We will deepen this topic in the paragraphs«Non-compliant causes» and «Downtime causes».
Causes
The «Production» section contains the list of products, the list of production orders, and the list of active productions at the moment.
We will deepen this topic in the paragraph «Productions».
Productions
In the «Utilities» section, there are three entries «Devices status monitor», «PLC Signals» and «User manual».
The first, gives access to the list of all devices involved and some control functions; the second shows the signals of a specific PLC; the third gives direct access to a web version manual.
We will deepen this topic in the paragraph «Utilities».
Utilities
The «Production line status» section lists the monitored lines.
Through this list you will be able to view the data of each line, relating to the Andon: you will be able to view the screen of the Andon board (TV LED) and also the screen of the touch panel.
We will deepen this topic in the paragraph «Production line status».
Production line status
The «Efficiency» section lists the monitored lines.
Through this list you will be able to view the OEE of today's turn, but you will also be able to view the OEE of that line in a certain period of time.
We will deepen this topic in the paragraph «Efficiency».

Users

The NIS web platform has several roles.
Using the "Users" button, you can add new users, associating it with one or more roles. Depending on the role, each user will have access to different views and functions.
Users and groups can be managed only if the logged in user has the «Administrator» level of rights.
Users
After clicking on the "Users" button, the user have access to the list of already registered users, displaying Name, Surname, username, e-mail, and the roles associated with each of them.
List of users

«Add»: by clicking it, we can add a new user.

«Edit»: by clicking it, we can modify a user after selecting it.

«Delete»: by clicking it, we can cancel a user after selecting it.

«Export XLS»: by clicking on it, we can export this table in Excel format.

«Groups management»: by clicking on it, we can edit an existing role or add a new role.

Functions
To add a new user, you have to click on "Add". This is the form to fill in to add a new user: "Code" (username) and "Name" are necessary.
Information

Groups

By clicking on "Groups management" you can access the list of existing roles. Currently they are: Administrator, Master Data Manager, OEE Managers and Supervisors.
Each role is enabled to perform specific functions:

Administrator: all functions enabled.

OEE manager: environment configurations, scrap and stop machine causes, OEE summary, reports.

Supervisor: all functions except users and groups management

The environment

The remaining entries of the menu "Environment", are used to define the environment in which the NIS system is operational.
So this section include the departments and lines involved, the length of the shifts, the cycle time adjustment, and the the scheduled pauses.
The environment

Departments

This section will show the list of departments where the NIS system is installed.
A department can contain one or more production lines.
The user who has the rights to edit this section can add new departments or edit/delete existing ones, or export this table in Excel format.
The departments

Production lines

This section will show the list of production lines where the NIS system is installed.
The user who has the rights to edit this section, can add new production lines or edit/delete existing ones, or export this table in Excel format.
Production lines
The user, when adds or edits an existing line, will have to set some values such as:

the department to which the line belongs

the number of workers (zero means gathered from ERP)

the number of shifts

setting OEE percentages, which will be represented by red, yellow and green

setting the Cycle Time Factor

setting the thresholds for OEE, failure, tooling and scraps reports (monthly and daily) (see also paragraph «Reports»)

Editing line

Shifts

this section will show the list of planned shifts.
The user can add a new shift, or edit an existing shift. He will have to set the start and end of each turn.
The user can also delete an existing shift.
Shifts

Cycle time % adjustment

The Cycle time is based on the cycle time gathered from ERP or manually entered by the operator in case of NO ERP data exchange.
It’s coupled by articole code and the line involved. Examples of coefficient adjustments.

50% => cycle time halved

100% => no change applied

200% => cycle time doubled

Cycle time % adjustment

Scheduled pauses

this section shows the list of scheduled pauses. The user can add a new scheduled pause.
Scheduled pauses
Before adding a new scheduled pause, the user will need to select a production line.
Start time and duration
Finally, the user have to specify the start time of the pause and its duration.
Selecting a production line

Non-compliant causes

The "Causes" section allows the user to manage both the causes of quality problems and machine stops
Non-compliant and downtime causes
The section Non-compliant causes shows the list of non-compliant causes provided.
The user can add a new cause, cancell or modify an existing one.
Non-compliant causes
When adding a new non-compliant cause, the user have to give a description and to associate a resource (a production line).
Adding a new non-compliant cause

Downtime causes

The downtime causes are all those causes that lead to a stop in production.
Causes can be of different kind (failure, scheduled or slowdown) and have been organized in three different depths, helping to define more and more in detail the cause of stop

Downtime causes – Lev. 1

This section shows the list of causes for first level.
Each item in the table specifies an identifier code, a description, the type (failure, scheduled or slowdown), the level (1st, 2nd or 3rd).
Downtime causes
The user who has the rights to edit this section can add new downtime causes or edit/delete existing ones, or export this table in Excel format.
Adding a new downtime causes, the user will have to set some values such as:

Code and ERP code

A description of the downtime causes (Ex. «Planned – Lunch»)

A type («Failure», «Scheduled» or «Slowdown»)

If it is or not, an organizational causes

The resource (line) involved

The level

Sort of index

OEE stratification (the user have to select a reason of the stop. See also the paragraph «Reports»)

Adding a downtime

Downtime causes – Lev. 2 & 3

The tables relating to the downtime causes of 2nd and 3rd levels are similar to each other, but are different from the table of the downtime causes of 1st level.
Downtime causes – Lev. 2 & 3
In these tables there is a column reporting the description of the previous level («Level 1» or «Level 2»): in this way it is clear at what level, each sub-level belongs.
Levels and sub-levels

Productions

In this section, the user will be able to manage all the products and related production orders and to view and modify the active productions.
Productions

Products

This section shows the list of all products.
Products
Adding a new product or editing an existing one, the user will have to set some values such as:

a code

a description

the related production line (optional)

Add a product

Production order

This section shows the list of production orders.
Production order
The information in this table relates to:

the article

the code of the production order

the ERP code

the number of items provided

the lines where it is possible to work the article, its cycle time and the number of workers involved

Production order table

Active productions

This section shows the list of active productions at this time.
The information in this table relates to the production order being processed in each line, the cycle time and the start time.
Active productions
Adding a new active production or editing an existing one, the user will have to provide some data:

the line

the production order

the takt time

Adding an active production

Utilities

The "Utilities" menu allows the user to navigate some aspects of hardware
Utilities

Devices status monitor

This section shows the list of all devices involved in the NIS system.
For all devices it is possible to know: IP address, MAC address, Name, Type (Tablet, PLC, Computer), Asset (NeXT ID), ID Kiosk, Status and History.
Devices
Through the column «Status» the user can to check the status of the device, if it is working or not.
Status
The "History" feature allows the user to see the history of the device's status. These are automatically recorded every 5 minutes.
History

PLC signals

This function allows the user to monitor the signals of a specific PLC.
Entering the PLC Asset Code (PLC NeXT ID) will display all PLC inputs. For each input we can know the type of signal associated and the number of received signals.
Green color means that the signal is 1 (the machine is running or a pieces is counted); white color means that the signal is 0 (the machine is stopped or a piece is not completed)
PLC signals

User manual

This function allows the user to open the NIS system guide in a web version.
User handbook

Reports

Through the NIS web application the user can view some reports.

Production line status

This section shows the list of departments involved in the NIS system.
Departments involved in the NIS system
By clicking on one of the departments (for example, «Hohlkorperline»), the user can see a summary of the real time efficiency of the lines (six in this case) in that department.
The summary of the real time efficiency
At the top on the right of each box there are two buttons:

the button on the left (1) allows to display the TV LED screen;

the button on the right (2) allows to display the touch panel screen.

TV LED and touch panel
(1) This is an example of a TV LED screen, present on each line.
The detailed description of the information shown on the LED TV can be found in the paragraph «The Andon board interface»
TV LED screen
(2) This is an example of a touch panel screen, present on each line.
The detailed description of the touch panel interface can be found in the paragraph «The touch panel interface»
Touch panel screen

Efficiency

This section shows the list of departments involved in the NIS system.
Departments involved in the NIS system
By clicking on one of the departments (for example, «Hohlkorperline»), the user can see a summary of the Overall Equipment Effectiveness (OEE) value
OEE summary
At the top on the right of each box there is a button. It allows:

to display the OEE value of that line, in a certain period

to access to some reports

OEE details
Thie following image shows the OEE interface. By default, it shows the OEE value of the current day, hour by hour, starting from the beginning of the shift.
OEE
At the top of the interface the user can choose the line to be analyzed, the time span to view (today, yesterday, current week, last week, current month, last month, current year last year).
OEE
Below, we find a series of buttons that allow the user to view a series of reports.
This topic will be discussed in the paragraph «Reports».
Reports
In the middle of the interface, a series of histograms show the OEE value, hour by hour.
The different colors refer to:

Yellow: stop for a quality problem (scrap)

Blue: speed loss

Red: stop machine

Green: the OEE

OEE
At the bottom of the interface you can see details about losses due to machine stops and scraps.
The duration of each stop is immediately visible.
Details about losses
By clicking on «Details» you can deepen the knowledge by going to see the start and end of each stop.
Details
Here the user can see the stops (not scheduled) that contribute to the amount of minutes we saw in the previous screen. For each stop we know the start time and the end time.
The user can export this table in excel format.
start and end of each stop
In the following chart, the user can find a variety of information.

total items produced

items processed for one hour

cadence

non-compliant items

time available

stop minutes

RF: Machine efficiency

RV: efficiency of machine availability

RQ: Object quality efficiency

OEE

Graph

Reports

From the OEE interface, the user can view a series of specific reports
Reports

Recalculate

The "Recalculate" function allows the NIS system to recalculate the OEE.
For example, this function is very useful if, at a later time, the cause of a stop has to be changed: from a stop programmed to an unplanned stop.
This change affects the calculation of OEE, so a recalculation is required.
Recalculate

Tabular OEE data

This feature allows the user to view all OEE data in tabular form. This table can also be exported to Excel format.
Tabular OEE data

OEE stratification

The "OEE stratification" function allows the user to view all causes of stop (block, minor stop, TPM, Scraps & Rework, Toolchange, Speed Losses, Startup / Shutdown) and the value of the OEE.
The goal is achieved using a graph that highlights the most frequent stops in the selected time span.
OEE stratification

Productions

This function allows the user to view a list of productions made in the selected time frame in a table format.
The user can read the order of production, the article code, the cycle time, the number of items produced, the number of non-compliant items, the start time of processing, the end time of processing.
Productions

Movements

This function allows the user to view the entire list of events, in the time interval selected: produced items, cycle time, type of movement (load or downtime), cause of downtime, type of downtime, duration of downtime, non-compliant items.
Movements

Cellboard Reports – OEE effective production

In this report, the user can see the monthly and daily OEE value (relative to the selected month).
In red, the user can see the treshold limit configured under "Production lines" in the "Environment" menu.
OEE effective production

Cellboard Reports – setup percentage

This function reports, on the left, as a percentage, the length of setup (tooling) over the entire time span (monthly).
On the right, this function shows, the time in minutes of setup, compared to the entire time span (daily).
Cellboard Reports – setup percentage

Cellboard Reports – setup average

This function shows the average length of the setup (tooling) in minutes, each month (on the left) or day by day in the selected month (on the right).
Cellboard Reports – setup average

Cellboard Reports – downtime percentage

This function reports, on the left, as a percentage, the length of downtime over the entire time span (monthly).
On the right, instead, this function shows, the time in minutes of downtime, compared to the entire time span (daily).
Cellboard Reports – downtime percentage

Cellboard Reports – downtime Pareto

This function shows the various causes of downtime that have occurred, in percentage, using the Pareto graph.
Cellboard Reports – downtime Pareto

Cellboard Reports – scrap items

This function reports, as a percentage, the length of scrap items over the entire time span (monthly on the left, daily on the right).
Cellboard Reports – scrap items

Cellboard Reports – scrap Pareto

This function shows the various causes of quality problems that have occurred, in percentage, using the Pareto graph.
Cellboard Reports – scrap Pareto

OEE overview

How does it works

The OEE overview is the central application for management. It allowed:

hierarchical organization of the Franke group based on macro areas

step by step focus on macro areas, plants, departmens, production resources

data warehouse used for computation

The hierarchical order is:

Franke

macroarea (eg "Sinks stainless steel")

plants

departments

production lines

The OEE overview menu
Once you click on a macro area, you can see:

the plants that are part of it (sub-locations).

the monthly OEE value (with graph)

the last day OEE value (with graph)

The macroarea view
Sub-locations tabular summary

OEE of selected month with trend indicator (related to the previous month) and % variation

OEE of last day with trend indicator (related to the previous day) and % variation

direct access to detailed information of the single sub-location

Sub-locations tabular summary
OEE of selected month

W: worked time (hours)

U: unplanned stops (hours)

P: planned stops (hours)

colors are based on OEE thresholds (same as andon boards)

Trend percentage between current selection and previous period

selected month => previous month

colors are based on predefined percentage values (-10%, -5%, 0, +5%, +10%)

OEE of selected month
OEE of last day

W: worked time (hours)

U: unplanned stops (hours)

P: planned stops (hours)

colors are based on OEE thresholds (same as andon boards)

Trend percentage between current selection and previous period

last month => the day before

colors are based on predefined percentage values (-10%, -5%, 0, +5%, +10%)

OEE of last day
Sub-locations graph summary

monthly OEE

daily OEE related to the selected period (month, year)

thresholds defined for C.I.C. reports

Sub-locations graph summary

The OEE

Definition

OEE (Overall Equipment Effectiveness) measures how close you are to perfect production (manufacturing only good parts, as fast as possible, with no stop time). OEE correlates real production with the ideal production planned.
The difference between these two values represents the loss of production in terms of:

RF = Availability (Time)

RV = Performance (Speed)

RQ = Quality

There are three kind of losses:

Availability Loss: an availability score of 100% means that the process is always running during planned production time (the time your process is scheduled to run). Any time the process is not running due to an unplanned stop (e.g., some type of mechanical failure) or a planned stop (e.g., cleaning) is an Availability Loss

Performance Loss: a performance score of 100% means that the process is running as fast as possible. Performance can be calculated as the ratio of Actual Run Rate to Theoretical Maximum Rate (the design capacity of a machine or process)

Quality Loss: a quality score of 100% means that the process is only making good parts. Quality is the ratio of Good Material to All Material. Some process applications only produce good materials, while others may have Quality Loss due to non-conforming materials.

How to calculate the OEE

The OEE is simplified in the multiplication of the indexes described above, then OEE = RF x RV x RQ

Availability (RF) = ? Run Time / ? Planned Production Time, that is >> RF=(d-s)/d [d=time availability; s=stops];

Performance = ? (Ideal Cycle Time × Total Parts) / ? Run Time that is >> RV=(CtxNp)/(d-s) [Ct= cycle time; Np=Number of pieces];

Quality = ? Good Parts / ? Total Parts, that is >> * RQ=(Np-Nc)/Np [Nc= non-compliant pieces]

NIS classifies stop-cause in 3 classes:

Not programmed Stop (F): it's required a causalization of stop

Programmed Stop (P): the worker set the begin and the end of this kind of stop using touch panel

Micro-stop (M): it's not required a causalization of the stop