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Production Performance Manager – How to systematically improve machine availability

Production Performance Manager Bosch Software Innovations
 
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Systematic improvement of machine availability

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The intelligent way to work with machine data


 
 

The Production Performance Manager is a production information and evaluation system. In near real time, it collects production and machine data, combines it to produce a visual representation, and communicates defined events to the production worker, who may be involved directly or indirectly.

 

Via its integrated Ticket Manager, the Production Performance Manager assigns rule-based tasks in electronic form, for example to initiate maintenance work or distribute aggregated production reports.

With the Production Performance Manager, you have an overview of the current condition of individual machines as well as the production system as a whole. As a result, reaction times are shorter, tasks clearly assigned, and information constantly available. This new availability of data and direct feedback provides optimum support for your continuous improvement process.

Production Performance Manager
 
 

Challenges to improving machine availability


Continuous improvement of production operations allows you to boost quality, cut costs, and increase output. All three aspects require needs-based action that doesn’t waste resources. To guarantee this, companies today have to counteract a wide range of challenges in their day-to-day production activities:

 
 

Visualizing production data

Evaluating machine data without IT skills

 

In manufacturing, individual employees often cannot view production and machine data, which is distributed throughout a heterogeneous group of machines with a wide variety of systems. However, to optimize production, this data – from machine control, for example – must be made easy for production experts to see in one consolidated place.

Data analysis usually lacks user-friendly solutions that can be implemented by the production experts themselves without involving the IT department. They should be able to directly create and evaluate flexible analyses for optimizing production. To do so, they need easy access to machine data that does not require any intervention in machine control.

 
 

Introducing intelligent repair and maintenance management

Machine downtimes and servicing at the wrong time lead to unnecessary costs and are a waste of resources. What you need instead is intelligent repair and maintenance management, which generates data from machine reports and delegates repair and maintenance orders to the appropriate employee. A knowledge database should provide support here so that the employee has ample and correct information for quickly carrying out the needed repair or maintenance.

 

 

Overview of the functions in the software solution


 
 

Visualizing machine data

Every improvement process is based on a sound data foundation. The first step is to make the data visible. Taking machine data from various sources, the Production Performance Manager visualizes it at one central point. The measured values are depicted live in a time series and as machine feedback, and can be viewed anywhere in the factory on the employee’s mobile device (PC, tablet, smartphone, etc.).

Visualizing machine data with the Production Performance Manager
 


 
Evaluating measured data with the Production Performance Manager

Users may opt to depict events on a timeline and can freely define various views.

Evaluating measured data

Users can evaluate the data themselves without any support from IT. Any amount of machine data can be selected that in the expert’s opinion has potential for improving the machine’s availability. In evaluating this data, users can turn to simple cause-and-effect analyses as well as rules that they can configure and activate to evaluate the machine data automatically.

Users can also subscribe to e-mail notifications to stay directly informed of defined incidents. For an expanded analysis, users may simply save recently selected data as a URL and forward it to other employees.

 


 

Taking action as needed and reviewing it with the Ticket Manager

The Ticket Manager optimizes service processes through tickets specific to a field of expertise, allowing experts in that field to make a fast and targeted response to events such as machine failure.

When a disturbance occurs, the system draws on aggregated machine notifications to automatically issue a ticket, which is added to a Kanban board overview.

Tickets are assigned based on the situation: this means that only those employees with the appropriate skill set and the necessary responsibility for the affected machine receive the ticket. In addition to automatic delegation, every ticket also comes with an escalation mechanism.

To ensure continuous maintenance and expansion of the knowledge database for the repair and maintenance service, solution recommendations can be stored in the regional language. The service process history serves as a basis for consistent optimization, and standardized reports make it possible to quickly identify long-term benefits.

Ticket Manager Production Performance Manager
 


 

Summary of functionalities


Architecture


 
Summary of the Production Performance Manager´s functionalities
Architecture and modules of the Production Performance Manager

The Production Performance Manager comprises a scalable modular system that is perfectly adapted to your requirements and can continuously be extended. Thanks to its open “generic interface,” you can quickly integrate machines, sensors, and other data sources in production IT into the software. And through a public API, it is possible to integrate third-party systems, too.

 
 

Benefits of the Production Performance Manager at a glance


 
 

Better application of expert know-how through

courtesy of optimized data access and central data analysis.

Flexibility without IT expertise so production experts themselves can implement use cases for machine monitoring.

Less downtime thanks to live data analysis in one central place and the implementation of faster service processes.

Production Performance Manager Bosch Software Innovations