Production Counter Assignments

Sepasoft MES Module Suite

Production Counters for OEE Metrics

OEE metrics use production counters. OEE calculations are done at the Line and Cell levels.

There are 4 types of counters:

  • Infeed
  • Outfeed
  • Reject
  • General

To get the best results for OEE calculation behavior:

  • When there is only one type of MES Counter for the Line (either just an Infeed counter or just one or more Outfeed counters), it/they must be created on the Line in the Production Model.

Note that having only one counter, created on a Cell in the Production Model, does not allow the Line OEE calculations to be calculated correctly.

  • When there are both an Infeed counter and an Outfeed counter (both on the Line, both on Cells, or a mix), make sure that the Infeed Count Equipment and Outfeed Count Equipment in the Material Definition  both point to the locations where the MES Counters were created in the Production Model.

Serial Cells

In these scenarios, each cell in the production line flows into the next cell, in series (there are no branches to the production line).

The diagram to the right shows all of the possible physical placements for photoeye detectors used to count the infeed, outfeed and reject parts in the examples below. The diagrams in the table below show where the MES Counters were created (which equipment).

The table below has some examples of various production line configurations, along with the OEE behavior that results based on how MES Counters are created in the Production Model and how the Material Definition counter selections are made.


# Scenario Production
Model 		Material
Definition

OEE Behavior

OEE Quality = (OEE Infeed - OEE Reject) / OEE Infeed

MES Counter Location Infeed Count Equip. Outfeed Count Equip.
1

Infeed

Line 1

Outfeed

n/a

Reject

n/a


Line 1


Line 1

[VALID]

  • OEE Outfeed = OEE Infeed
  • Reject = 0
  • Quality = 100%


2

Infeed

n/a

Outfeed

Line 1

Reject

n/a


Line 1


Line 1

[VALID]

  • OEE Infeed = OEE Outfeed
  • Reject = 0
  • Quality = 100%


3

Infeed

Line 1

Outfeed

n/a

Reject

Cell 1
and
Cell 2


Line 1


Line 1

[VALID]

  • OEE Outfeed = OEE Infeed - sum of rejects
  • Reject = sum of rejects on cells
  • Quality = calculated


4

Infeed

n/a

Outfeed

Line 1

Reject

Cell 1
and
Cell 2


Line 1


Line 1

[VALID]

  • OEE Infeed = OEE Outfeed - sum of rejects
  • Reject = sum of rejects on cells
  • Quality = calculated


5

Infeed

Cell 1

Outfeed

n/a

Reject

Cell 1 and Cell 2


Cell 1


Line 1

[VALID]

  • OEE Outfeed = OEE Infeed - sum of rejects
  • Reject = sum of rejects on cells
  • Quality = calculated

Included in Sepasoft Versions:

Warning

MES 2.81.0 SP12 and later
MES 2.79.0 SP12 and later

MES 3.81.1 SP7 and later
MES 3.79.0 SP7 and later

6

Infeed

n/a

Outfeed

Cell 3

Reject

Cell 1 and Cell 2


Line 1


Cell 3

[VALID]

  • OEE Infeed = OEE Outfeed - sum of rejects
  • Reject = sum of rejects on cells
  • Quality = calculated

Included in Sepasoft Versions:

Warning

MES 2.81.0 SP12 and later
MES 2.79.0 SP12 and later

MES 3.81.1 SP7 and later
MES 3.79.0 SP7 and later

7

Infeed

Cell 1

Outfeed

Cell 3

Reject

n/a


Cell 1


Cell 3

[VALID]

  • Reject = Infeed - Outfeed
    (taking into account scaling and package count)
  • Quality = incorrect


8

Infeed

Cell 1

Outfeed

Cell 3

Reject

Cell 1
and
Cell 2


Cell 1


Cell 3

[VALID]

Ideal configuration:

  • Provides full capability of counting Infeed, Outfeed and Rejects
  • Calculates Performance and Quality correctly


9

Infeed

n/a

Outfeed

Line 1

Reject

Line 1


Line 1


Line 1

[VALID] 

  • OEE Infeed = Outfeed - sum of rejects
    (taking into account scaling and package count)
    (better accuracy than scenarios 3 and 4 above)


Parallel Cells

In the scenarios below, the production line utilizes divergent (parallel) packaging cell options.

In this example, items manufactured in previous cells can be diverted into one of two packaging cells, Case or Tray, for shipping products either by the case or by the tray, based on the demand for each in the market.

The diagram to the right shows all of the possible physical placements for photoeye detectors used to count the infeed, outfeed and reject parts in the examples below. The diagrams in the table below show where the MES Counters were created (which equipment).

The table below has some examples of various production line configurations, along with the OEE behavior that will result based on how MES Counters are created in the Production Model and how the Material Definition counter selections are made.

# Scenario Production
Model

Material
Definition

OEE Behavior
MES Counter Location Infeed Count Equip. Outfeed Count Equip.
10


Infeed

n/a

Outfeed

Line 1
(both packers)

Reject

n/a


Line 1


Line 1

[VALID] 

  • OEE Outfeed = OEE Infeed
  • Reject = 0
  • Quality = 100%

Note: Runs using the Case Packer will drive Case Packer Outfeed counter up. Runs using Tray Packer will push Tray Packer Outfeed counter up.


11

Infeed

n/a

Outfeed

Cell 3
and
Cell 4

Reject

n/a


Line 1


Cell 3*
or
Cell 4*

[NOT VALID] 

  • OEE Infeed = 0
  • Quality = incorrect
  • Performance = incorrect

Note: Place both of the Outfeed counters on Line 1 instead.


12


Infeed

Cell 1

Outfeed

Cell 3
and
Cell 4

Reject

n/a


Cell 1


Cell 3*
or
Cell 4*

[VALID] 

  • Reject = Outfeed - Infeed
    (taking into account scaling and package count)


13


Infeed

Line 1

Outfeed

Cell 3
and
Cell 4

Reject

n/a


Line 1


Cell 3*
or
Cell 4*

[VALID] 

  • Reject = Outfeed - Infeed
    (taking into account scaling and package count)


* Either Cell 3 or Cell 4, depending on the Material being manufactured.

Adding Additional Factors


Sepasoft MES Module Suite