Equipment MES Data Acquisition Networking Calculation Formulas and Technical SolutionsOEE Energy Consumption Crop Rate Qualified Efficiency Injection Moulding Machines Manipulators Tinning Machines Laminating Machines OPC ua/modbus TCP/http
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Equipment Failure Rate Equipment Failure Time / Total Equipment Power On and Off Time * 100% Failure Time: Mode 1 Calculated by Repair Start and End Time. "Function customisation:
I. Plus maintenance pause and start
II. Abnormality category
1. Quality abnormality
2. Planning scheduling abnormalities
3.Production abnormalities
4. Equipment abnormalities
(Only this classification of maintenance
(only the repair time of this category is counted in the equipment failure rate)
Statistical display depending on the category (MTTR, MTBF, etc.)
"
Average repair time Total equipment repair time (sum of all repair times)/total number of repairs within 30 days Maintenance records through the equipment management system, the time can be filtered
Equipment OEE Availability * Performance Efficiency * Quality Pass Rate
Crop rate Equipment effective production operating time / scheduled running time * 100% "Equipment effective production operating time: the cumulative time that the equipment state is running state
Scheduled running time: the total time that the equipment is powered on and started up"
Performance efficiency Actual output * Theoretical beat time/Equipment effective production operation time Actual output, theoretical beat time: confirm whether to fill in by hand according to the equipment. If there is no data, the performance efficiency is 1
Quality pass rate Number of qualified products/total number of products produced If there is no qualified number, the pass rate is 1.
Energy consumption Monthly energy consumption, 24-hour energy consumption, real-time energy consumption.
Equipment MES Data Requirements
Coating machine Energy consumption, number of qualified products, product production cycle, number of qualified products Energy consumption data including monthly energy consumption, 24-hour energy consumption, real-time energy consumption
Air conditioner Energy consumption of external machine, real-time temperature of inlet and outlet water.
Annealing Furnace Energy consumption, temperature, speed, basket operation cycle, number of qualified products.
Dedusting room Production cycle, number of qualified products
UV painting room Production cycle, number of qualified products
UV/IR curing oven Energy consumption, temperature, rotation speed, operating cycle of each station, number of qualified products.
Anti-mist spraying room Production cycle, number of qualified products
Anti-mist curing oven Energy consumption, temperature, rotational speed, operating cycle of the basket, number of qualified products Docking method
Waste treatment equipment Energy consumption Docking content Treatment
FFU Energy consumption, air speed.
MES Data Collection Requirements for All Devices (every device has to do it)
Item Formula Remarks
Equipment Failure Rate Equipment Failure Time/Equipment Power-On Time*100%.
Equipment Crop Rate Equipment Effective Production Operation Time/Scheduled Operation Time*100%.
Average repair time Total equipment repair time (sum of all repair times)/total number of repairs in 30 days
Equipment maintenance interval
Equipment OEE Crop rate*Performance efficiency*Quality pass rate
Crop rate Effective production operation time of the equipment/total time of equipment power-on and start-up*100% Operation flag
Performance efficiency Actual output*Theoretical beat time/Equipment effective production operation time*100% Processing quantity
Quality pass rate Number of qualified products/Total production quantity*100% Processing quantity
Energy consumption Monthly energy consumption, 24-hour energy consumption, real-time energy consumption, if there is, then take it or not.
Equipment MES data special requirements (need to collect)
Laminating machine Process parameters (file name, descent time, holding time, rise time)
Manipulator None
Injection moulding machine "Injection moulding machine core process parameters
Temperature control parameters
Cylinder temperature (segment monitoring: charging section / compression section / metering section / nozzle)
Mould temperature (real time values for moving / fixed mould sections)
Oil temperature (hydraulic system working temperature)
Pressure and speed parameters
Injection pressure (peak / holding phase step values)
Clamping force (deviation between real time and set point)
Screw speed (RPM in plasticising phase)
Injection speed (mm/s with multi-stage speed profile)
Time parameters
Cooling time (mould thermostat return temperature correlation)
Mould opening and closing time (including buffer stage time consuming)
Production cycle time (Takt Time)
Production data parameters
Cumulative production (good/bad product classification)
Number of mould cavities (pressure balance between cavities in case of multi-cavity moulds)
Energy consumption data (real-time power curve and energy consumption per unit)
Status parameters
Equipment status (running/standby/fault/alarm codes)
Mould life (linked to mould change cycles through counters)".
Tinning machine Process parameters (tin time, iron temperature, iron life count, speed percentage, file name)
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