Ethernet™ is a trademark of Xerox Corporation. microSD™ is a registered trademark of SanDisk Corporation. LIMITED WARRANTY AND LIMITATION OF LIABILITY For more information about the warranty and limitation of liability, please contact the Horner Solutions Group Manager at 877-665-5666 or visit our website at www.hornersolution.com...
MAN1348-01-EN_OEE_UM Table of Contents PREFACE ............................2 LIMITED WARRANTY AND LIMITATION OF LIABILITY ................2 Table of Contents ............................3 SAFETY AND COMPLIANCE ......................5 Safety Warnings and Guidelines ....................5 INTRODUCTION ..........................7 OEE Overview..........................7 Production Data Availability ....................... 8 Types of Reports .........................
MAN1348-01-EN_OEE_UM SAFETY AND COMPLIANCE Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Electrical Shock Hazard. Warning: Consult user documentation. WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections.
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MAN1348-01-EN_OEE_UM All applicable codes and standards need to be followed in the installation of this product. For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger. Adhere to the following safety precautions whenever any type of connection is made to the module. a) Connect the green safety (earth) ground first before making any other connections.
INTRODUCTION OEE Overview The Horner OEE Solution is a pre-programmed system that is easy and quick to implement with no further programming development required by the user end. After a simple initialization setup via the touchscreen interface (CONFIG /SETUP area), the OEE kit will start collecting and monitoring production data immediately, though more complex configuration is available as well.
Each of these cases will be handled on a case-by-case basis determined by volume of the opportunity, who requested the modification. Finally, a signed NDA protecting the IP of this product for the Horner Solutions Group is needed, including who will support the application changes that are made and what the costs are that are associated with the individual project requirements.
Ideally, a ground resistance measurement from equipment to earth ground is 0Ω. In reality, it typically is higher. The U.S. National Electrical Code (NEC) states the resistance to ground shall not exceed 25Ω. Horner APG recommends less than 15Ω resistance from our equipment to ground. Resistance greater than 25Ω can cause undesirable or harmful interference to the device.
MAN1348-01-EN_OEE_UM OEE SYSTEM NAVIGATION Home Home is the central navigation and status screen that displays whenever the system is powered on. Access to Work interfaces, Trends, Summaries, Downtime accumulators, and other features are available from Home. All ‘Back’, ‘Exit’, and ‘Home’ buttons eventually lead to Home. August 10, 2022 12 | P a g e...
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MAN1348-01-EN_OEE_UM 5.1.1 Screen Header The banner at the top of the screen displays the Cell identifier text and the current Part, as well as the current system time and date. If downtime is currently active, a notification is displayed here. The Downtime description may display as ‘No Code’...
MAN1348-01-EN_OEE_UM See: 14.2 Shift Configuration 5.1.5 System Navigation Access to Trends, Summaries, Events, Downtime accumulators, Call accumulators, the Call interface, and OEE Configuration are available via these navigation buttons. See: 5.2 Trends See: 5.3 Summary See: 5.4 Events See: 5.5 Downtime Accumulators See: 5.6 Call Accumulators See:...
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MAN1348-01-EN_OEE_UM 5.2.1 Main Trend Screen – OEE and All Components 5.2.2 Availability Score Trend 5.2.3 Performance Score Trend August 10, 2022 15 | P a g e...
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MAN1348-01-EN_OEE_UM 5.2.4 Quality Score Trend 5.2.5 OEE Score Trend August 10, 2022 16 | P a g e...
MAN1348-01-EN_OEE_UM Summary The Summary gives an overview of the current shift and any shifts not currently active that have completed within the past 24 hours. A block is shown for each 15-minute slice of time during the shift. A block may be colored grey to indicate it is either in the future or was scheduled break time. The block is colored Red, Yellow, or Green to reflect the linked score at the end of that time segment.
MAN1348-01-EN_OEE_UM Downtime Accumulators The accumulated downtime for each downtime code is shown in a chart format. The total amount of downtime is shown for each Shift. Scheduled Changeover time that has accumulated is shown. If there is any unassigned downtime accumulating, it is shown at the top of the screen. Call Accumulators The amount of time each call has been active and unacknowledged is shown for each shift.
MAN1348-01-EN_OEE_UM CALLS The Call interface is available from the Home interface, from all Work interfaces, and from the Login interface. It allows a machine operator to make calls to one or more departments via light tower notification and, if configured, e-mail notification. Accessing this screen is also how a call is acknowledged or cleared by the corresponding department after they have responded to the call.
MAN1348-01-EN_OEE_UM Acknowledging a Call When the appropriate department responds to the Call, they should Acknowledge the Call. Access the Call Interface, then press the corresponding ‘Acknowledge Call’ button. If e-mail has been configured and the timeout expires before the Call has been Acknowledged, a follow- up e-mail is sent to an additional address if so configured.
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MAN1348-01-EN_OEE_UM All active Calls can be cleared at once by pressing the ‘Clear All’ button. The blue tower light will become inactive once there are no active calls. To maintain flexibility, Calls can be Cleared without first Acknowledging them. This allows for a Call that is quick to address, such as Raw Materials delivering parts and addressing the Call without first making an extra trip to the station to acknowledge the Call.
MAN1348-01-EN_OEE_UM CONFIGURATION Configuration Overview The Config button provides a password prompt to access the configuration of the OEE system. The password prompt screen also displays versions that may assist with technical support when needed. Options to copy files from a USB drive to the installed MicroSD card are provided to allow datalog and configuration files to be transferred.
MAN1348-01-EN_OEE_UM Touch the desired menu option or use the up/down arrow keys to highlight the selection, then press ↵. Cell Configuration August 10, 2022 23 | P a g e...
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MAN1348-01-EN_OEE_UM 7.2.1 Plant ID Information that is included with Log files to identify this plant location. This will help corporate applications identify data from different plant locations. 7.2.2 Cell ID Information that is included with Log files to identify individual work cell within a plant or multi-plant application 7.2.3 Data log Interval Setting...
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MAN1348-01-EN_OEE_UM After that initial trigger, Availability and Quality scoring is always calculated once per second. The ‘OEE Calculations’ configuration option allows Performance scoring and total OEE scoring to be calculated once per second in the same fashion or calculated only when a new cycle occurs when in Uptime. During downtime, all components of OEE are calculated once per second.
MAN1348-01-EN_OEE_UM Shift Configuration Note: Batch Mode operation does not require the configuration provided by the separate configuration utility. For Shift Mode operations, Shift configuration via the touchscreen interface is currently simplified. Full Shift Mode configuration can be done with the configuration utility. See: 14.2 Shift Configuration 7.3.1...
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MAN1348-01-EN_OEE_UM 7.3.2 1st / 2nd / 3rd Shift Configuration Enter Start and End times for the shift. The shift duration is calculated based on these setup parameters. Up to four pre-determined breaks can be scheduled. Breaks are not included in Planned Production Time.
MAN1348-01-EN_OEE_UM Part Editor/Viewer See also: 14.1 Part Configuration The Part Editor/Viewer allows the creation of different part numbers to be manufactured at each work cell. Each part has parameters as described below. Each part configuration is saved as a file on the MicroSD memory installed in the OEE system.
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MAN1348-01-EN_OEE_UM Changeover Time: Enter the time (hh:mm:ss) allowed to complete a part changeover to this part on this work cell If set to 0 seconds, automatic downtime will occur when the part parameters determine a timeout. Changeover mode is ignored. If set to 1 second, automatic downtime will never occur due to the Changeover process.
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MAN1348-01-EN_OEE_UM number of parts. The option of ‘Touchscreen Scrap Entry’ is presented when ‘Touchscreen’ is selected and provides options for ‘Cycle Time’, ‘Hourly’, or ‘End of Shift’. Touchscreen Scrap Entry: Currently has no effect, possible future expansion. Scrap Trigger – Sensor: When set to ‘Sensor’, scrap triggers are via the I2 I/O terminal on the OEE system.
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MAN1348-01-EN_OEE_UM NOTE: All of the Batch Mode Ranges and Targets are ignored if the OEE system is operating in Shift Mode. Back: Return to the Part Editor / Viewer 7.4.2 Load Part From Flash Use this button to load an existing part file into the Part Editor/Viewer. A directory of parts is displayed. Select one by touching the file name or using the arrow keys to highlight the desired part, then press the ↵...
MAN1348-01-EN_OEE_UM Downtime Code Configuration Up to 20 Downtime Codes can be configured for selection at downtime events. By default, 12 Downtime Codes are enabled as follows: Operator Shortage (Not Editable; See Automatic Downtime Codes in System Configuration) Upstream Blockage (Not Editable; See Automatic Downtime Codes in System Configuration) Changeover (Not Editable;...
MAN1348-01-EN_OEE_UM Ethernet Configuration The Ethernet Configuration is used to allow connection of this OEE cell to a data concentrator. This may require IT personnel to properly configure. The Ethernet connection also allows FTP access for transfer of configuration and datalog files. Set the IP Address, Network Mask, and Gateway Address according to IT guidelines in the facility where the OEE system is installed.
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MAN1348-01-EN_OEE_UM 7.6.2 FTP Example Using Windows File Explorer as an example to connect using FTP to an OEE panel at 192.168.1.1, type the FTP target into the address bar, then press Enter: Enter the Username and Password when prompted, then click ‘Log On’: Note: The original window may remain open and blank while another window opens with the contents of the OEE system.
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MAN1348-01-EN_OEE_UM All files pertaining to the OEE system are held in the ‘OEE’ directory. Files can be copied/pasted or dragged/dropped to and from this window from other windows. For the best results, files should be copied to the local PC before attempting to open. August 10, 2022 35 | P a g e...
MAN1348-01-EN_OEE_UM Email Configuration See also: 7.6 Ethernet Configuration Setup 7.7.1 Email SMTP Server To initiate e-mails from the OEE system, an overall Email Configuration is first needed. This could be an internal e-mail server provided by the IT department or an external service, e.g. Gmail. In any case, proper Ethernet Configuration is required, followed by proper Email SMTP server configuration.
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MAN1348-01-EN_OEE_UM Ping Address: Provided as a troubleshooting tool on this screen. For example, a possible DNS address can be entered here and, if the Response Time comes back as something other than -1ms, that address is visible to this OEE system. Successfully pinging 8.8.4.4 will confirm a path to the internet. Status: Status is provided to help with troubleshooting.
MAN1348-01-EN_OEE_UM System Information Select System Information is shown for configuration and/or troubleshooting purposes. System Time: Allows you to view and change the real-time clock time (hh:mm:ss) in 24 hour time format System Date: Allows you to view and change real-time clock date (dd-Mmm-yyy) Touchscreen Beep: Any press of the touchscreen normally produces a beep from the OEE system.
Scheduled Breaks and Changeover; Effect on Scoring Part of the flexibility of the Horner OEE system is the ability to allow for configuration of scheduled break times and part changeovers. Scheduling these times relaxes the scoring to account for those times...
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MAN1348-01-EN_OEE_UM by shortening the Planned Production Time (PPT) used in both Availability and Performance scoring. Zeroing these times keeps the scoring running instead of pausing them for breaks or changeover. Determining whether to configure Breaks or Changeover time is something that must be determined based on what is needed from the OEE system.
MAN1348-01-EN_OEE_UM LOGIN / LOGOUT Log In For an operator to run the work cell, they must be logged in for the Work Interfaces to be available. Click on the flashing LOG IN button from Home to login. The time and date of the last Login Database Update is shown. Tap the ‘Login ID’...
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MAN1348-01-EN_OEE_UM Tap the ‘Password’ field and use the resulting keypad to enter a Password followed by the ‘Enter’ button. Once both fields have been entered, press the ‘LOGIN’ button. If a valid Login ID and Password combination has been entered, Home is immediately displayed and the Logged In user is shown. Otherwise, a message showing ‘Invalid Login’...
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MAN1348-01-EN_OEE_UM Log Out To log out of the OEE system, press ‘LOG OUT’ from Home. The Logout interface will display and prompt for confirmation. The user that is currently logged in is shown and the option is given to LOG OUT or CANCEL. Selecting the ‘LOG OUT’...
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MAN1348-01-EN_OEE_UM 10 WORK INTERFACES Work interfaces display details about the ongoing process and provide an interface for manual operation. The banner at the top shows the Cell identifier and the Part currently selected. The current time and date are also displayed. 10.1 Work: Detailed Target Parts: The ‘Parts’...
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MAN1348-01-EN_OEE_UM Target Scores: The targets shown are those configured for either the current shift or the current part depending on Shift mode or Batch mode operation. Good / Scrap: The Good part count and Scrap part count are shown along with a bar graph visualization of the Good/Bad split.
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MAN1348-01-EN_OEE_UM Realtime OEE Scores: The Availability, Performance, Quality, and resulting OEE scores are shown as a bar graph representation as well as the scores themselves. They are color-coded per the configuration. Home: Returns the user to the Home interface. Change Part: Allows the user to select a different part to produce. The current part configuration is shown, along with the option to select a new part.
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MAN1348-01-EN_OEE_UM 10.2 Work: Simplified This Work interface provides a simplified set of process data and an interface for manual operation. The banner at the top shows the Cell identifier and the Part currently selected. The current time and date are also displayed. Total Parts: The total number of parts is shown above the Add Cycle button.
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MAN1348-01-EN_OEE_UM Cell Status: A selection for ‘RUNTIME’ and ‘DOWNTIME’ is provided for changing the cell status manually. Running time accumulations for Uptime and Downtime are shown. Other system events may trigger UP or DOWN time automatically, such as the triggering of another cycle or the expiration of the grace period.
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MAN1348-01-EN_OEE_UM 10.3 Work: Basic This Work screen displays a basic set of process data and an interface for manual operation. The banner at the top shows the Cell identifier and the Part currently selected. The current time and date are also displayed.
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MAN1348-01-EN_OEE_UM 11 DOWNTIME Downtime is time that will negatively affect OEE scoring. A Downtime Code is required as an explanation of any downtime that occurs. Downtime can be triggered manually by the user or it can be triggered automatically according to the current part configuration. During Downtime, the Uptime timer stops accumulating and the Downtime timer starts accumulating.
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MAN1348-01-EN_OEE_UM 11.4 Automatic Downtime Code Entry The first three Downtime Codes are meant for automatic specification and cannot be changed in the System Configuration. Each of these codes can be separately configured to be automatically selected with no user input needed if the proper conditions exist. These will only be automatically specified if the option is turned on in the System Configuration.
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MAN1348-01-EN_OEE_UM 12 PART CHANGEOVER From any Work interface, the operator is allowed the option to select a different part. Depending on System Configuration, this will restart OEE calculations when in Batch mode or initiate the next step of the OEE calculations when in Shift mode. The ‘Change Part’...
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MAN1348-01-EN_OEE_UM part is highlighted. If the part was created with any spaces in the name, the part file name will be truncated at the first instance of the space character. Press the ↵ key once the new part is selected and confirm the selection. The newly selected part configuration is shown on the screen, but these parameters have not yet taken effect.
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MAN1348-01-EN_OEE_UM 13 DATA LOGGING AND STORAGE All manufacturing production data is recorded and stored on the MicroSD memory card installed in the OEE system. The data files are stored in a comma-separated value (CSV) file format that is easy to open in spreadsheet software for use in production analysis and reporting.
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MAN1348-01-EN_OEE_UM Maint_Active_Sec Raw Seconds total Maintenance Active Call Time as of Event Maint_Unack_Sec Raw Seconds total Maintenance Unacknowledged Call Time as of Event Super_Active_Sec Raw Seconds total Supervisor Active Call Time as of Event Super_Unack_Sec Raw Seconds total Supervisor Unacknowledged Call Time as of Event 13.1.2 Process Logs OEE\DATALOGS = Process datalog files for each shift.
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MAN1348-01-EN_OEE_UM Down_HrMinSec[0] Total Downtime accumulation as of this entry, formatted Hr:Min:Sec Up_Seconds Total Uptime accumulation as of this entry, raw seconds Down_Seconds Total Downtime accumulation as of this entry, raw seconds 13.1.3 Downtime Logs OEE\DOWNTIME = Downtime event log for each shift. Every downtime event is logged as an entry to this file.
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MAN1348-01-EN_OEE_UM OEE\PART = Storage for Part files. This is the only directory that is accessible by the operator from which to select a new part for Changeover. New parts created with the Part Editor / Viewer are saved here. Subdirectories may be made to group parts if needed. OEE = Directory where configuration files must be placed for the OEE system to load.
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MAN1348-01-EN_OEE_UM 14 CONFIGURATION UTILITY Much of the OEE configuration can be done via the OEE Touchscreen itself using the password- protected Configuration menu. However, some of the more tedious configuration is better served using the companion Configuration Utility. For Shift Mode usage, the full Shift Configuration requires use of the Configuration Utility at this time.
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MAN1348-01-EN_OEE_UM 14.1 Part Configuration Part Configuration allows for creation of Part files that can then be selected when changing parts on the OEE system. Part files may also be created or edited via the OEE touchscreen interface as noted elsewhere in this manual. Each parameter for part configuration is available for editing.
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MAN1348-01-EN_OEE_UM Changeover Time: To schedule Changeover Time as time that will not negatively affect OEE scoring, enter the amount of time expected to change the machine over to this part. Any time exceeding this without exiting Changeover Mode will be added to Downtime. If set to 0 seconds, automatic downtime will occur when the part parameters determine a timeout.
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MAN1348-01-EN_OEE_UM Downtime and a Downtime Code must be selected before Work can continue. This is intended for manual triggering where cycles may not be added on a real-time basis yet still expected. • End of Shift: Automatic Downtime is disabled. Cycles may be entered at any time during the shift.
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MAN1348-01-EN_OEE_UM Create Part File: Once the parameters have been altered as desired for this part, click the ‘Create Part File’ button. A confirmation window will display the location of the file, which is the same directory in which this configuration utility is placed. If a part file by the same name already exists, a prompt to overwrite will appear before the file is written.
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MAN1348-01-EN_OEE_UM Shift Start/End: Set the Start and End times for the shift. Total Shift Length is calculated from these values. Break Start/End: Break times can be configured or left zeroed depending on the intended production analysis: • If scheduled break times are not to be included in Planned Production Time, configure up to 4 breaks per shift.
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MAN1348-01-EN_OEE_UM Create Shift File: Once the parameters have been altered as desired for any shift, click the ‘Create Shift File’ button for the corresponding shift. A confirmation window will display the location of the file, which is the same directory in which this configuration utility is placed. If a shift file for this shift already exists, a prompt to overwrite will appear before the file is written.
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MAN1348-01-EN_OEE_UM 14.3 Downtime Code Configuration Configuration of the available downtime codes can be configured here or within the password protected OEE Config menu on the OEE touchscreen. These downtime codes will be available to select in the event of downtime that is either manually or automatically triggered.
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MAN1348-01-EN_OEE_UM same directory in which this configuration utility is placed. If a downtime code file already exists, a prompt to overwrite will appear before the file is written. The resulting file is named DTC.CFG. Downtime Code File Location: Downtime Code files created with this utility should be placed on the MicroSD card of the OEE system in the OEE directory.
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MAN1348-01-EN_OEE_UM Fill in the 20 available spots for Login ID and the corresponding Password. The Login IDs will be included in datalogging as a record of the operator logged in at the time of any datalogged event. Login IDs and Passwords can be any positive number up to 999999999 (9 digits).
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MAN1348-01-EN_OEE_UM 14.5 Email / SMS Configuration With up to 30 Email addresses that can be configured for various Call and End-of-Shift functions, the Configuration Utility can make this process easier compared to touchscreen entry. Though it still requires an Email service, it is possible to Email directly to a mobile number. Cellular service carriers may provide Email-to-Text options for Mobile Numbers so that these messages appear as a text message rather than an Email.
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MAN1348-01-EN_OEE_UM 15 DATA CONCENTRATOR The Data Concentrator is a separate device that is meant to compile select data from up to 32 OEE Cells. When 16 or less OEE Cells are monitored, each Cell’s data is shown in full. When 17 or more OEE Cells are monitored, space becomes limited. Configuration allows selection of whether the Cell Name or the Current Part Name is displayed for each monitored Cell.
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MAN1348-01-EN_OEE_UM Connection between OEE Cells and the Data Concentrator is accomplished via Ethernet. Therefore, each OEE Cell and the Data Concentrator itself must be set to a known IP address and have valid Ethernet settings. The IP address for each Cell will then be entered into the configuration for the Data Concentrator.
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MAN1348-01-EN_OEE_UM To configure any OEE Cell to be monitored, toggle the button in any location to ON. Empty space between cells is possible for visual separation. Any cell enabled in the 17-32 column will cause the “Limited Space” screen to display, which gives the choice of showing either the Cell ID or Current Part for any given OEE Cell.
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MAN1348-01-EN_OEE_UM To access the Data Concentrator with a web browser, enter the IP address of the Data Concentrator into the address bar. For example, http://10.0.0.1 using the default address. This requires a path between the browser device and the Data Concentrator via Ethernet in some fashion. This path may exist only when signed onto a specific facility’s network, or it may be available from anywhere on the internet.
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MAN1348-01-EN_OEE_UM 16 MODBUS TCP ACCESS The Horner OEE System is a Modbus TCP/IP Server. Information can be monitored by any other device or software package that is able to be a Modbus TCP/IP Client. 16.1 Configuration Information A limited number of configuration parameters are available via Modbus TCP/IP Holding Registers as follows.
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MAN1348-01-EN_OEE_UM 16.2 OEE Data OEE data can be found in the Accumulators via Modbus TCP/IP Holding Registers as follows. Each Each Accumulator accumulator consists of a total of 28 Words of data as described following this table. contains data as described in Section 16.2.1.
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1C29 Light Tower Linked to OEE BOOL 1 Bit 17 CONTACT INFORMATION To contact the factory, please contact the Horner Solutions Group Manager at 877-665-5666 or visit our website at www.hornersolution.com August 10, 2022 75 | P a g e...
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MAN1348-01-EN_OEE_UM INDEX 1st / 2nd / 3rd Shift Configuration ...... 27 FTP Example ............34 Accumulator Data Assembly ....... 75 General Shift Configuration ......... 26 Acknowledging a Call .......... 20 Ground Specifications ......... 11 Automatic Changeover Downtime ..... 51 Grounding Definition ........... 11 Automatic Downtime ..........
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MAN1348-01-EN_OEE_UM Safety Warnings and Guidelines ......5 Table of Contents ..........3 Save Part To Flash ..........31 Trends ..............14 Scheduled Breaks and Changeover; Effect on Types of Reports ............ 8 Scoring ............. 39 Update Part Currently Loaded......31 Screen Background ..........
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