@seedtactics/insight-client 16.8.0 → 16.8.1

This diff represents the content of publicly available package versions that have been released to one of the supported registries. The information contained in this diff is provided for informational purposes only and reflects changes between package versions as they appear in their respective public registries.
Files changed (150) hide show
  1. package/README.md +23 -29
  2. package/dist/assets/index-BGjv3-QV.js +388 -0
  3. package/dist/cell-status/current-status.js +4 -1
  4. package/dist/cell-status/estimated-cycle-times.js +2 -1
  5. package/dist/cell-status/inspections.js +1 -1
  6. package/dist/cell-status/loading.js +1 -1
  7. package/dist/cell-status/material-summary.js +4 -2
  8. package/dist/cell-status/names.js +1 -1
  9. package/dist/cell-status/rebookings.js +3 -1
  10. package/dist/cell-status/scheduled-jobs.js +1 -1
  11. package/dist/cell-status/sim-production.js +6 -2
  12. package/dist/cell-status/station-cycles.js +3 -1
  13. package/dist/cell-status/tool-replacements.js +21 -7
  14. package/dist/cell-status/tool-usage.js +7 -2
  15. package/dist/components/App.d.ts +2 -2
  16. package/dist/components/App.js +13 -5
  17. package/dist/components/AxisAndGrid.d.ts +6 -6
  18. package/dist/components/BarcodeScanning.d.ts +2 -2
  19. package/dist/components/BarcodeScanning.js +8 -2
  20. package/dist/components/ChartTooltip.d.ts +2 -2
  21. package/dist/components/ChooseMode.js +6 -1
  22. package/dist/components/ChooseOperator.d.ts +1 -1
  23. package/dist/components/ErrorsAndLoading.d.ts +3 -3
  24. package/dist/components/LoadingIcon.d.ts +1 -1
  25. package/dist/components/LoadingIcon.js +1 -1
  26. package/dist/components/LogEntry.d.ts +2 -2
  27. package/dist/components/LogEntry.js +10 -8
  28. package/dist/components/ManualSerialEntry.d.ts +2 -2
  29. package/dist/components/MonthSelect.d.ts +1 -1
  30. package/dist/components/MonthSelect.js +3 -1
  31. package/dist/components/Navigation.d.ts +2 -2
  32. package/dist/components/Navigation.js +1 -1
  33. package/dist/components/VerboseLogging.d.ts +1 -1
  34. package/dist/components/analysis/AnalysisSelectToolbar.d.ts +1 -1
  35. package/dist/components/analysis/BasketCycleCards.d.ts +1 -1
  36. package/dist/components/analysis/BasketCycleCards.js +1 -1
  37. package/dist/components/analysis/BufferChart.d.ts +1 -1
  38. package/dist/components/analysis/BufferChart.js +23 -4
  39. package/dist/components/analysis/CostPerPiece.d.ts +2 -2
  40. package/dist/components/analysis/CostPerPiece.js +2 -2
  41. package/dist/components/analysis/CycleChart.d.ts +1 -1
  42. package/dist/components/analysis/CycleChart.js +17 -4
  43. package/dist/components/analysis/DataTable.js +4 -2
  44. package/dist/components/analysis/EfficiencyPage.d.ts +2 -2
  45. package/dist/components/analysis/EfficiencyPage.js +1 -1
  46. package/dist/components/analysis/HeatChart.d.ts +1 -1
  47. package/dist/components/analysis/HeatChart.js +12 -3
  48. package/dist/components/analysis/InspectionDataTable.d.ts +1 -1
  49. package/dist/components/analysis/InspectionDataTable.js +6 -1
  50. package/dist/components/analysis/InspectionSankey.d.ts +1 -1
  51. package/dist/components/analysis/InspectionSankey.js +16 -6
  52. package/dist/components/analysis/PalletCycleCards.d.ts +1 -1
  53. package/dist/components/analysis/PalletCycleCards.js +5 -3
  54. package/dist/components/analysis/PartCycleCards.d.ts +2 -2
  55. package/dist/components/analysis/PartCycleCards.js +16 -6
  56. package/dist/components/analysis/QualityPage.d.ts +1 -1
  57. package/dist/components/analysis/ScheduleHistory.d.ts +1 -1
  58. package/dist/components/analysis/ScheduleHistory.js +1 -1
  59. package/dist/components/analysis/StationDataTable.d.ts +1 -1
  60. package/dist/components/analysis/ToolReplacements.d.ts +1 -1
  61. package/dist/components/analysis/ToolReplacements.js +7 -3
  62. package/dist/components/operations/AllMaterial.d.ts +1 -1
  63. package/dist/components/operations/ChartRangeEdit.d.ts +1 -1
  64. package/dist/components/operations/ChartRangeEdit.js +13 -4
  65. package/dist/components/operations/CloseoutReport.js +1 -1
  66. package/dist/components/operations/CompletedParts.js +2 -2
  67. package/dist/components/operations/CurrentWorkorders.js +2 -2
  68. package/dist/components/operations/Dashboard.d.ts +2 -2
  69. package/dist/components/operations/OEEChart.d.ts +4 -4
  70. package/dist/components/operations/OEEChart.js +7 -2
  71. package/dist/components/operations/Outliers.d.ts +1 -1
  72. package/dist/components/operations/Programs.js +9 -4
  73. package/dist/components/operations/Rebookings.d.ts +1 -1
  74. package/dist/components/operations/Rebookings.js +3 -1
  75. package/dist/components/operations/RecentCycleChart.d.ts +1 -1
  76. package/dist/components/operations/RecentCycleChart.js +2 -2
  77. package/dist/components/operations/RecentProduction.js +3 -3
  78. package/dist/components/operations/RecentSchedules.js +3 -1
  79. package/dist/components/operations/RecentStationCycles.d.ts +1 -1
  80. package/dist/components/operations/RecentStationCycles.js +1 -1
  81. package/dist/components/operations/ShiftSettings.d.ts +1 -1
  82. package/dist/components/operations/SimDayUsage.d.ts +1 -1
  83. package/dist/components/operations/ToolReport.js +17 -6
  84. package/dist/components/operations/WorkorderGantt.d.ts +1 -1
  85. package/dist/components/quality/QualityMaterial.d.ts +2 -2
  86. package/dist/components/quality/QualityMaterial.js +1 -1
  87. package/dist/components/quality/QualityPaths.d.ts +1 -1
  88. package/dist/components/quality/RecentFailedInspections.d.ts +1 -1
  89. package/dist/components/routes.d.ts +1 -1
  90. package/dist/components/routes.js +1 -1
  91. package/dist/components/station-monitor/BulkRawMaterial.d.ts +2 -2
  92. package/dist/components/station-monitor/BulkRawMaterial.js +11 -5
  93. package/dist/components/station-monitor/Closeout.js +6 -2
  94. package/dist/components/station-monitor/Inspection.js +3 -1
  95. package/dist/components/station-monitor/InvalidateCycle.d.ts +3 -3
  96. package/dist/components/station-monitor/InvalidateCycle.js +10 -3
  97. package/dist/components/station-monitor/JobDetails.js +4 -2
  98. package/dist/components/station-monitor/LoadStation.d.ts +1 -1
  99. package/dist/components/station-monitor/LoadStation.js +6 -3
  100. package/dist/components/station-monitor/Material.d.ts +10 -10
  101. package/dist/components/station-monitor/Material.js +28 -20
  102. package/dist/components/station-monitor/Material.test.js +1 -1
  103. package/dist/components/station-monitor/MoveMaterialArrows.d.ts +2 -2
  104. package/dist/components/station-monitor/PrintedLabel.d.ts +3 -3
  105. package/dist/components/station-monitor/PrintedLabel.js +9 -4
  106. package/dist/components/station-monitor/QuarantineButton.d.ts +1 -1
  107. package/dist/components/station-monitor/QuarantineButton.js +4 -2
  108. package/dist/components/station-monitor/Queues.d.ts +2 -2
  109. package/dist/components/station-monitor/Queues.js +6 -4
  110. package/dist/components/station-monitor/QueuesAddMaterial.d.ts +3 -3
  111. package/dist/components/station-monitor/QueuesAddMaterial.js +20 -7
  112. package/dist/components/station-monitor/SelectInspType.d.ts +2 -2
  113. package/dist/components/station-monitor/SelectWorkorder.d.ts +1 -1
  114. package/dist/components/station-monitor/StationToolbar.d.ts +1 -1
  115. package/dist/components/station-monitor/StationToolbar.js +13 -3
  116. package/dist/components/station-monitor/SystemOverview.d.ts +4 -4
  117. package/dist/components/station-monitor/SystemOverview.js +36 -16
  118. package/dist/components/station-monitor/Whiteboard.d.ts +1 -1
  119. package/dist/data/all-material-bins.js +2 -1
  120. package/dist/data/cost-per-piece.js +3 -1
  121. package/dist/data/move-arrows.js +3 -1
  122. package/dist/data/part-summary.js +1 -1
  123. package/dist/data/results.cycles.js +13 -4
  124. package/dist/data/tools-programs.js +3 -2
  125. package/dist/index.html +1 -1
  126. package/dist/network/api.d.ts +18 -0
  127. package/dist/network/api.js +502 -371
  128. package/dist/util/chart-colors.js +12 -1
  129. package/docs/client-efficiency.md +226 -263
  130. package/docs/client-engineering.md +27 -28
  131. package/docs/client-launch.md +32 -33
  132. package/docs/client-operations.md +50 -53
  133. package/docs/client-quality.md +39 -43
  134. package/docs/client-sales.md +36 -40
  135. package/docs/client-scanners.md +27 -27
  136. package/docs/client-station-monitor.md +86 -96
  137. package/docs/client-tools-programs.md +47 -44
  138. package/docs/improve-fms.md +73 -78
  139. package/docs/makino.md +21 -25
  140. package/docs/material-quarantine.md +50 -64
  141. package/docs/material-tracking.md +162 -195
  142. package/docs/mazak.md +78 -91
  143. package/docs/niigata.md +145 -168
  144. package/docs/operator-procedures.md +72 -76
  145. package/docs/part-instructions.md +36 -36
  146. package/docs/security.md +87 -81
  147. package/docs/server-config.md +36 -45
  148. package/docs/server-errors.md +21 -22
  149. package/package.json +25 -24
  150. package/dist/assets/index-BwbaiELK.js +0 -364
@@ -2,34 +2,29 @@
2
2
  title: FMS Monthly Flexibility Analysis
3
3
  nav: FMS Insight Client > Flexibility Analysis
4
4
  description: >-
5
- The FMS Insight flexibility analysis pages are used by managers to view
6
- a monthly report on the system and to focus on continuous improvement.
7
- The pages highlight potential bottlenecks and places for efficiency improvements
8
- in the cell.
5
+ The FMS Insight flexibility analysis pages are used by managers to view a monthly report on the
6
+ system and to focus on continuous improvement. The pages highlight potential bottlenecks and
7
+ places for efficiency improvements in the cell.
9
8
  ---
10
9
 
11
10
  # FMS Insight Monthly Flexibility Analysis
12
11
 
13
- FMS Insight supports continuous improvement by assisting with a monthly review.
14
- We suggest that approximately once a month, all stakeholders review the operation of the cell and
15
- decide on potential improvements. The [improve an FMS](improve-fms)
16
- documentation goes into more details about how to make the most of these
17
- efficiency calculations.
12
+ FMS Insight supports continuous improvement by assisting with a monthly review. We suggest that
13
+ approximately once a month, all stakeholders review the operation of the cell and decide on
14
+ potential improvements. The [improve an FMS](improve-fms) documentation goes into more details about
15
+ how to make the most of these efficiency calculations.
18
16
 
19
17
  ![Screenshot of choosing analysis month](screenshots/insight-choose-analysis-month.png)
20
18
 
21
- At the top of the page are two radio buttons allowing you to analyze either the last
22
- 30 days or a specific calendar month. You can then select from a variety of reports
23
- to investigate the cell.
19
+ At the top of the page are two radio buttons allowing you to analyze either the last 30 days or a
20
+ specific calendar month. You can then select from a variety of reports to investigate the cell.
24
21
 
25
- The best metric for continuous improvement of an FMS is not cost/piece but
26
- instead is the bottlenecks and utilization of system resources (the
27
- goal is to produce more stuff with the same machines and quality). The
28
- efficiency tab shows some charts and graphs for a monthly summary of the
29
- operation of the cell, displaying reports that in our experience are very
30
- helpful to find and fix bottlenecks. We suggest you review this data once a
31
- month and use these reports to gradually alter the flexibility or operation
32
- of the cell to improve the performance.
22
+ The best metric for continuous improvement of an FMS is not cost/piece but instead is the
23
+ bottlenecks and utilization of system resources (the goal is to produce more stuff with the same
24
+ machines and quality). The efficiency tab shows some charts and graphs for a monthly summary of the
25
+ operation of the cell, displaying reports that in our experience are very helpful to find and fix
26
+ bottlenecks. We suggest you review this data once a month and use these reports to gradually alter
27
+ the flexibility or operation of the cell to improve the performance.
33
28
 
34
29
  ## Efficiency
35
30
 
@@ -37,319 +32,287 @@ of the cell to improve the performance.
37
32
 
38
33
  ![Screenshot of buffer occupancy chart](screenshots/insight-buffer-occupancy.png)
39
34
 
40
- As material moves through the system, it buffers before various operations. It can buffer
41
- on a pallet waiting on the inbound rotary table, it can buffer on a pallet in the
42
- stocker waiting for either machining or unloading, or it can buffer between processes
43
- in a [transfer queue](material-tracking). In general, material will buffer right in
44
- front of the bottleneck operation. The buffer occupancy chart can thus be used to determine
45
- which operation (machining, loading, unloading) is the current bottleneck and also how the
46
- bottleneck changes over time.
47
-
48
- The buffer occupancy chart calculates a moving average of the quantity of material buffered
49
- in all these various places. The x-axis is the days of the month. For each time on
50
- the x-axis, a window around that point is used to calculate the average quantity of material
51
- in the buffer during the window of time. This average quantity is graphed on the y-axis.
52
-
53
- Using a moving average window smooths out the jitter from individual pallet moves,
54
- for example when a pallet rotates into the machine and another pallet is quickly
55
- sent to the inbound rotary. The size of the window can be controlled by the slider
56
- in the top-right. The size of the window should be set so that the major trends are
57
- visible while short oscillations are smoothed out.
58
-
59
- In an efficient, well-running system the bottleneck is always machining. This will be
60
- reflected in the buffer occupancy chart with the "Stocker[Waiting for unload]" line zero
61
- or almost zero, the "Rotary" for each machine always above zero, the
62
- "Stocker[Waiting for machining]" only positive if all rotary tables are full, and any
63
- in-process transfer queues small. If instead the load stations become the bottleneck,
64
- the buffer occupancy chart will show a rise either "Stocker[Waiting for unload]" or a
65
- rise in the in-process transfer queue between processes. Also, the rotary buffer
35
+ As material moves through the system, it buffers before various operations. It can buffer on a
36
+ pallet waiting on the inbound rotary table, it can buffer on a pallet in the stocker waiting for
37
+ either machining or unloading, or it can buffer between processes in a
38
+ [transfer queue](material-tracking). In general, material will buffer right in front of the
39
+ bottleneck operation. The buffer occupancy chart can thus be used to determine which operation
40
+ (machining, loading, unloading) is the current bottleneck and also how the bottleneck changes over
41
+ time.
42
+
43
+ The buffer occupancy chart calculates a moving average of the quantity of material buffered in all
44
+ these various places. The x-axis is the days of the month. For each time on the x-axis, a window
45
+ around that point is used to calculate the average quantity of material in the buffer during the
46
+ window of time. This average quantity is graphed on the y-axis.
47
+
48
+ Using a moving average window smooths out the jitter from individual pallet moves, for example when
49
+ a pallet rotates into the machine and another pallet is quickly sent to the inbound rotary. The size
50
+ of the window can be controlled by the slider in the top-right. The size of the window should be set
51
+ so that the major trends are visible while short oscillations are smoothed out.
52
+
53
+ In an efficient, well-running system the bottleneck is always machining. This will be reflected in
54
+ the buffer occupancy chart with the "Stocker[Waiting for unload]" line zero or almost zero, the
55
+ "Rotary" for each machine always above zero, the "Stocker[Waiting for machining]" only positive if
56
+ all rotary tables are full, and any in-process transfer queues small. If instead the load stations
57
+ become the bottleneck, the buffer occupancy chart will show a rise either "Stocker[Waiting for
58
+ unload]" or a rise in the in-process transfer queue between processes. Also, the rotary buffer
66
59
  occupancy will drop to zero.
67
60
 
68
61
  #### Station Use
69
62
 
70
63
  ![Screenshot of Station Use Heatmap](screenshots/insight-analysis-station-oee.png)
71
64
 
72
- The Station Use heatmap shows the station usage over the month. On the x-axis
73
- are the days of the month and on the y-axis are the machines and load
74
- stations. There are three charts which can be selected in the top-right
75
- corner: "Standard OEE", "Planned OEE", and "Occupied".
65
+ The Station Use heatmap shows the station usage over the month. On the x-axis are the days of the
66
+ month and on the y-axis are the machines and load stations. There are three charts which can be
67
+ selected in the top-right corner: "Standard OEE", "Planned OEE", and "Occupied".
76
68
 
77
69
  - The "Standard OEE" chart computes the actual overall equipment effectiveness (OEE) over the month.
78
70
  For each station and each day, FMS Insight uses the log of parts produced and adds up the expected
79
- operation time for each part cycle and then divides by 24 hours
80
- to obtain a percentage that the station was busy with productive work. (If station cycles
81
- were longer than expected, this extra time is not counted in the OEE.) For each grid cell in the chart, the OEE percentage is drawn
82
- with a color with darker colors higher OEE and lighter colors lower OEE. A grid cell
83
- can be moused over to obtain extra information in a tooltip.
84
-
85
- - The "Planned OEE" chart displays the simulated station usage for the downloaded jobs and
86
- is the prediction of what the OEE should look like based on all the schedules for the month.
87
-
88
- - The "Occupied" chart computes the total percentage of time that a pallet is occupying the station. For
89
- each station and each day, FMS Insight uses the log of events to determine when a pallet arrives
90
- and departs from each station. The total time a pallet is at the station is then divided by 24 hours
91
- to obtain a percentage that the station was occupied. These percentages are then charted with darker colors
92
- higher occupancy.
93
-
94
- The Station Use heatmaps are useful for several observations. First, the Occupied heatmap can be used to
95
- determine the overall usage of the load station. If the load station occupied percentages are very high,
96
- it can indicate that the load station is a bottleneck and preventing the cell from performing useful work.
97
- In a healthy cell, the load stations should be faster than the machines,
98
- so the load stations should be empty at least part of the time waiting for machining to finish.
99
-
100
- The difference between the Standard OEE and Occupied heatmaps can be useful to determine if there is a lot
101
- of cycle interruptions. For example, if a program is expected to take 25 minutes but spends 40 minutes at
102
- the machine, the Standard OEE heatmap will be credited with 25 minutes and the Occupied heatmap will be
103
- credited with 40 minutes, causing the Occupied heatmap to be darker in color for that day. Now, cycle
104
- interruptions do occasionally happen; comparing the Standard OEE and Occupied heatmaps allows you to
105
- determine if these are one-off events or a consistent problem. If most days are darker on the Occupied
106
- heatmap, the cycle interruptions should be investigated in more detail. (For example, look at individual parts on the
107
- machine cycle charts, ensure the expected time entered into the schedule is actually correct, investigate
108
- machine maintenance records, etc.)
109
-
110
- Finally, the Standard OEE heatmap helps visualize how balanced the machines were loaded over the month.
111
- We want to see all the machines consistently roughly the same color. If you see that
112
- a machine has a lighter color for a couple days, that indicates either the machine was down or
113
- that the daily mix for that day did not have enough flexibility. You should then consider
114
- picking a part and extending that part to run on the lightly loaded machine. To find such a
115
- part, you can use the part production chart below to see which part mix was run on this day
116
- to help find a part that might be changed to run on the lightly loaded machine.
71
+ operation time for each part cycle and then divides by 24 hours to obtain a percentage that the
72
+ station was busy with productive work. (If station cycles were longer than expected, this extra
73
+ time is not counted in the OEE.) For each grid cell in the chart, the OEE percentage is drawn with
74
+ a color with darker colors higher OEE and lighter colors lower OEE. A grid cell can be moused over
75
+ to obtain extra information in a tooltip.
76
+
77
+ - The "Planned OEE" chart displays the simulated station usage for the downloaded jobs and is the
78
+ prediction of what the OEE should look like based on all the schedules for the month.
79
+
80
+ - The "Occupied" chart computes the total percentage of time that a pallet is occupying the station.
81
+ For each station and each day, FMS Insight uses the log of events to determine when a pallet
82
+ arrives and departs from each station. The total time a pallet is at the station is then divided
83
+ by 24 hours to obtain a percentage that the station was occupied. These percentages are then
84
+ charted with darker colors higher occupancy.
85
+
86
+ The Station Use heatmaps are useful for several observations. First, the Occupied heatmap can be
87
+ used to determine the overall usage of the load station. If the load station occupied percentages
88
+ are very high, it can indicate that the load station is a bottleneck and preventing the cell from
89
+ performing useful work. In a healthy cell, the load stations should be faster than the machines, so
90
+ the load stations should be empty at least part of the time waiting for machining to finish.
91
+
92
+ The difference between the Standard OEE and Occupied heatmaps can be useful to determine if there is
93
+ a lot of cycle interruptions. For example, if a program is expected to take 25 minutes but spends 40
94
+ minutes at the machine, the Standard OEE heatmap will be credited with 25 minutes and the Occupied
95
+ heatmap will be credited with 40 minutes, causing the Occupied heatmap to be darker in color for
96
+ that day. Now, cycle interruptions do occasionally happen; comparing the Standard OEE and Occupied
97
+ heatmaps allows you to determine if these are one-off events or a consistent problem. If most days
98
+ are darker on the Occupied heatmap, the cycle interruptions should be investigated in more detail.
99
+ (For example, look at individual parts on the machine cycle charts, ensure the expected time entered
100
+ into the schedule is actually correct, investigate machine maintenance records, etc.)
101
+
102
+ Finally, the Standard OEE heatmap helps visualize how balanced the machines were loaded over the
103
+ month. We want to see all the machines consistently roughly the same color. If you see that a
104
+ machine has a lighter color for a couple days, that indicates either the machine was down or that
105
+ the daily mix for that day did not have enough flexibility. You should then consider picking a part
106
+ and extending that part to run on the lightly loaded machine. To find such a part, you can use the
107
+ part production chart below to see which part mix was run on this day to help find a part that might
108
+ be changed to run on the lightly loaded machine.
117
109
 
118
110
  #### Part Production
119
111
 
120
112
  ![Screenshot of Part Production Heatmap](screenshots/insight-analysis-part-completed.png)
121
113
 
122
- The Part Production heatmap shows the distribution of completed parts over
123
- the month. On the x-axis are the days of the month and on the y-axis are the
124
- part types. For each part and each day, FMS Insight counts how many parts
125
- were produced that day. For each grid cell in the chart, the entry
126
- is drawn as a color with darker colors higher machine hours and lighter colors lower
127
- machine hours. A grid cell can be moused over to obtain extra information in a
128
- tooltip.
129
-
130
- The part production OEE heatmap is mainly useful to visualize the part mix as it
131
- varies throughout the month, by comparing the relative color shades. Also, it can help
132
- find a part to change move onto a lightly loaded machine. For example, consider that a machine
133
- is found to be lightly loaded via the station OEE heatmap. That same day can be viewed on
134
- the part production OEE heatmap and the darkest colored part was the highest run that day and
135
- could be considered to be extended to be run on the lightly loaded machine.
136
-
137
- Note that these heatmaps should only be used to brainstorm ideas. We would still
138
- to investigate if expanding `yyy` to include machine 2 would increase overall
139
- system performance. Are there enough pallets? How many extra inspections are required?
140
- Will this cause a traffic jam? These questions can be answered using simulation, _SeedTactic: Designer_,
141
- Little's Law, or a tool such as our [SeedTactic: Planning](https://www.seedtactics.com/features#seedtactic-planning).
114
+ The Part Production heatmap shows the distribution of completed parts over the month. On the x-axis
115
+ are the days of the month and on the y-axis are the part types. For each part and each day, FMS
116
+ Insight counts how many parts were produced that day. For each grid cell in the chart, the entry is
117
+ drawn as a color with darker colors higher machine hours and lighter colors lower machine hours. A
118
+ grid cell can be moused over to obtain extra information in a tooltip.
119
+
120
+ The part production OEE heatmap is mainly useful to visualize the part mix as it varies throughout
121
+ the month, by comparing the relative color shades. Also, it can help find a part to change move onto
122
+ a lightly loaded machine. For example, consider that a machine is found to be lightly loaded via the
123
+ station OEE heatmap. That same day can be viewed on the part production OEE heatmap and the darkest
124
+ colored part was the highest run that day and could be considered to be extended to be run on the
125
+ lightly loaded machine.
126
+
127
+ Note that these heatmaps should only be used to brainstorm ideas. We would still to investigate if
128
+ expanding `yyy` to include machine 2 would increase overall system performance. Are there enough
129
+ pallets? How many extra inspections are required? Will this cause a traffic jam? These questions can
130
+ be answered using simulation, _SeedTactic: Designer_, Little's Law, or a tool such as our
131
+ [SeedTactic: Planning](https://www.seedtactics.com/features#seedtactic-planning).
142
132
 
143
133
  ## Cycle Analysis
144
134
 
145
- If the broad analysis above indicates a problem, the cycle analysis can be used
146
- to investigate the problem in more detail.
135
+ If the broad analysis above indicates a problem, the cycle analysis can be used to investigate the
136
+ problem in more detail.
147
137
 
148
138
  #### Machine Cycles
149
139
 
150
140
  ![Screenshot of station cycle chart](screenshots/insight-machinecycle-graph.png)
151
141
 
152
- The machine cycle chart displays a point for each program cycle. The cycles
153
- can be filtered by a specific part, a specific program, a specific machine, a
154
- specific pallet or a combination. The x-axis is the days of the month and the
155
- y-axis is cycle time in minutes. The cycle time is the wall clock time
156
- between program start and program end of the machine. The legend at the
157
- bottom shows which colors correspond to which stations, and by clicking on
158
- stations in the legend you can enable or disable the viewing of specific
159
- stations. By clicking on a point you can obtain details about that specific
160
- cycle in a tooltip and open the material card for the cycle. Finally, the
161
- chart can be zoomed by clicking and dragging.
162
-
163
- When a specific part and specific program are selected, a gray background and
164
- black horizontal line are shown. The gray background is calculated to be the
165
- statistical median and deviation of the points; the middle of the gray band is
166
- the median of the program time and the width of the band is determined by calculating
167
- the median absolute deviation of the median (MAD). In contrast, the horizontal
168
- black line is the expected cycle time entered during scheduling and sent in
169
- the scheduled jobs. Thus if the horizontal black line differs
170
- significantly from the middle of the gray band, this means that likely the expected
171
- time used in the simulation and scheduling is incorrect.
172
-
173
- The example screenshot above is an example of a part program which looks
174
- good. We see that almost all of the machine cycles are around 40 minutes,
175
- within the gray band and the horizontal black line and there are only a
176
- couple machine cycles significantly longer than 40 minutes which likely come
177
- from program interruptions, tool problems, etc. Since there are only a couple
178
- outlier points, we might instead conclude that it is not worth the effort to
179
- spend a large amount of time focusing on this part. If instead the graph
180
- showed many points outside the gray band and longer than 40 minutes, it would
181
- be worth it to investigate and improve the part program and tooling.
142
+ The machine cycle chart displays a point for each program cycle. The cycles can be filtered by a
143
+ specific part, a specific program, a specific machine, a specific pallet or a combination. The
144
+ x-axis is the days of the month and the y-axis is cycle time in minutes. The cycle time is the wall
145
+ clock time between program start and program end of the machine. The legend at the bottom shows
146
+ which colors correspond to which stations, and by clicking on stations in the legend you can enable
147
+ or disable the viewing of specific stations. By clicking on a point you can obtain details about
148
+ that specific cycle in a tooltip and open the material card for the cycle. Finally, the chart can be
149
+ zoomed by clicking and dragging.
150
+
151
+ When a specific part and specific program are selected, a gray background and black horizontal line
152
+ are shown. The gray background is calculated to be the statistical median and deviation of the
153
+ points; the middle of the gray band is the median of the program time and the width of the band is
154
+ determined by calculating the median absolute deviation of the median (MAD). In contrast, the
155
+ horizontal black line is the expected cycle time entered during scheduling and sent in the scheduled
156
+ jobs. Thus if the horizontal black line differs significantly from the middle of the gray band, this
157
+ means that likely the expected time used in the simulation and scheduling is incorrect.
158
+
159
+ The example screenshot above is an example of a part program which looks good. We see that almost
160
+ all of the machine cycles are around 40 minutes, within the gray band and the horizontal black line
161
+ and there are only a couple machine cycles significantly longer than 40 minutes which likely come
162
+ from program interruptions, tool problems, etc. Since there are only a couple outlier points, we
163
+ might instead conclude that it is not worth the effort to spend a large amount of time focusing on
164
+ this part. If instead the graph showed many points outside the gray band and longer than 40 minutes,
165
+ it would be worth it to investigate and improve the part program and tooling.
182
166
 
183
167
  ![Screenshot of station cycle table](screenshots/insight-machinecycle-table.png)
184
168
 
185
- The cycles can be toggled to display the raw data in a table instead of a chart.
186
- The table can be filtered, sorted, and restricted to a specific date range. The resulting
187
- raw data can be copied to the clipboard to be pasted into a spreadsheet for further analysis.
169
+ The cycles can be toggled to display the raw data in a table instead of a chart. The table can be
170
+ filtered, sorted, and restricted to a specific date range. The resulting raw data can be copied to
171
+ the clipboard to be pasted into a spreadsheet for further analysis.
188
172
 
189
173
  #### Load/Unload Cycles
190
174
 
191
175
  ![Screenshot of load station cycle chart](screenshots/insight-loadcycle-graph.png)
192
176
 
193
- The load/unload cycle chart displays a point for each load or unload event.
194
- The x-axis is the days of the month and the y-axis is time in minutes.
195
- The cycles can be filtered by a specific part or pallet. The chart will display one of
196
- three possible times for each operation: "L/U Occupancy", "Load (estimated)", and "Unload (estimated)".
177
+ The load/unload cycle chart displays a point for each load or unload event. The x-axis is the days
178
+ of the month and the y-axis is time in minutes. The cycles can be filtered by a specific part or
179
+ pallet. The chart will display one of three possible times for each operation: "L/U Occupancy",
180
+ "Load (estimated)", and "Unload (estimated)".
197
181
 
198
182
  The "L/U Occupancy" chart displays a point for the wall clock time that the pallet spends at the
199
- load station; the time from the pallet arriving at the load station until the operator presses
200
- the ready button. This is the time that FMS Insight collects and stores
201
- so this chart displays the actual raw data collected.
202
-
203
- Despite being the actual data FMS Insight collects, the "L/U Occupancy" chart
204
- is hard to use to determine if there are problems or slowdowns in loading a
205
- specific part. The recorded time is the wall clock time from pallet arrival
206
- to departure so includes all the operations which occur at the load station
207
- which might include a load and an unload or just a load or just an unload.
208
- Thus, FMS Insight attempts to split the wall clock occupied time of the
209
- pallet at the load station among the various operations such as loading or
210
- unloading that occurred.
211
-
212
- For each cycle, FMS Insight splits the time the pallet spends at the load
213
- station among each piece of material being loaded, transferred, or unload. To
214
- do so, FMS Insight uses the list of material loaded/unloaded/transferred and
215
- calculates the expected time the operation should take based on the values
216
- entered into the scheduled jobs. The expected time is
217
- then used to calculate a percentage consumption for each material, and this
218
- percentage is then applied to the actual wall clock time of the pallet
219
- occupancy. For example, consider an operation where part _aaa_ is loaded and
220
- part _bbb_ is unloaded. The schedule says that the loading of _aaa_ should
221
- take 5 minutes and the unloading of _bbb_ should take 8 minutes for a total
222
- time the pallet should spend at the load station of 13 minutes. Now say that
223
- the pallet actually spent 15 minutes at the load station. The load of _aaa_
224
- is expected to consume `5/13 = 38%` of the cycle and the unload of _bbb_ is
225
- expected to consume `8/13 = 62%` of the cycle. The 38% is multiplied by the
226
- actual wall clock time of 15 minutes to give approximately 5.8 minutes for
227
- the load of _aaa_. Similarly for the unload of _bbb_, 15 minutes times 62% is
228
- approximately 9.2 minutes. Note how the "extra" 2 minutes (15 minutes
229
- compared to 13 minutes) for the entire cycle is divided among both the load
230
- and the unload operation. This calculation is repeated separately for each
231
- load/unload cycle.
232
-
233
- The result of FMS Insight's estimated splitting is graphed in the "Load
234
- Operation (estimated)" and "Unload Operation (estimated)" charts selected in
235
- the top-right corner. The screenshot above shows the "Load Operation
236
- (estimated)" chart. For each load/unload cycle, FMS Insight splits the time
237
- as described above and then plots a point with the y-coordinate the
238
- calculated time, filtering the data to a specific part and/or pallet. (In the
239
- example from the previous paragraph, the points would have y-coordinate 5.8
240
- and 9.2 minutes.) Exactly like the machine cycles, FMS Insight calculates the
241
- median and median absolute deviation of the points and plots them as a gray band
242
- in the background. Finally, the expected time entered into the
243
- scheduled jobs is graphed as a horizontal black line.
183
+ load station; the time from the pallet arriving at the load station until the operator presses the
184
+ ready button. This is the time that FMS Insight collects and stores so this chart displays the
185
+ actual raw data collected.
186
+
187
+ Despite being the actual data FMS Insight collects, the "L/U Occupancy" chart is hard to use to
188
+ determine if there are problems or slowdowns in loading a specific part. The recorded time is the
189
+ wall clock time from pallet arrival to departure so includes all the operations which occur at the
190
+ load station which might include a load and an unload or just a load or just an unload. Thus, FMS
191
+ Insight attempts to split the wall clock occupied time of the pallet at the load station among the
192
+ various operations such as loading or unloading that occurred.
193
+
194
+ For each cycle, FMS Insight splits the time the pallet spends at the load station among each piece
195
+ of material being loaded, transferred, or unload. To do so, FMS Insight uses the list of material
196
+ loaded/unloaded/transferred and calculates the expected time the operation should take based on the
197
+ values entered into the scheduled jobs. The expected time is then used to calculate a percentage
198
+ consumption for each material, and this percentage is then applied to the actual wall clock time of
199
+ the pallet occupancy. For example, consider an operation where part _aaa_ is loaded and part _bbb_
200
+ is unloaded. The schedule says that the loading of _aaa_ should take 5 minutes and the unloading of
201
+ _bbb_ should take 8 minutes for a total time the pallet should spend at the load station of 13
202
+ minutes. Now say that the pallet actually spent 15 minutes at the load station. The load of _aaa_ is
203
+ expected to consume `5/13 = 38%` of the cycle and the unload of _bbb_ is expected to consume
204
+ `8/13 = 62%` of the cycle. The 38% is multiplied by the actual wall clock time of 15 minutes to give
205
+ approximately 5.8 minutes for the load of _aaa_. Similarly for the unload of _bbb_, 15 minutes times
206
+ 62% is approximately 9.2 minutes. Note how the "extra" 2 minutes (15 minutes compared to 13 minutes)
207
+ for the entire cycle is divided among both the load and the unload operation. This calculation is
208
+ repeated separately for each load/unload cycle.
209
+
210
+ The result of FMS Insight's estimated splitting is graphed in the "Load Operation (estimated)" and
211
+ "Unload Operation (estimated)" charts selected in the top-right corner. The screenshot above shows
212
+ the "Load Operation (estimated)" chart. For each load/unload cycle, FMS Insight splits the time as
213
+ described above and then plots a point with the y-coordinate the calculated time, filtering the data
214
+ to a specific part and/or pallet. (In the example from the previous paragraph, the points would have
215
+ y-coordinate 5.8 and 9.2 minutes.) Exactly like the machine cycles, FMS Insight calculates the
216
+ median and median absolute deviation of the points and plots them as a gray band in the background.
217
+ Finally, the expected time entered into the scheduled jobs is graphed as a horizontal black line.
244
218
 
245
219
  #### Pallet Cycles
246
220
 
247
221
  ![Screenshot of pallet cycle chart](screenshots/insight-analysis-pallets.png)
248
222
 
249
- Select a pallet from the combo box in the top-right. Once selected, all
250
- pallet cycles are displayed. The x-axis is the days of the month and the
251
- y-axis is the pallet cycle time in minutes. A pallet cycle time is the wall
252
- clock time from when a pallet leaves the load station to the next time it
253
- leaves the load station. This will therefore include cart transfer time,
254
- buffer time, machining time, and load/unload time. By clicking on a point,
255
- you can obtain more information about the pallet cycle in a tooltip.
256
- Similarly to the station cycle chart, the pallet cycle chart can be zoomed by
257
- clicking and dragging or the zoom range can be manually set via the button in
258
- the bottom-right.
259
-
260
- The pallet cycle chart is best used to determine if the cell is running lean
261
- and validate the [daily allocation and scheduling
262
- technique](https://www.seedtactics.com/docs/tactics/preventing-traffic-jams)
263
- to determine if there are traffic jams occurring in the pallets. In a lean,
264
- healthy cell, most pallet cycles should be low and reasonably consistent. If
265
- pallet cycle times vary wildly, there is likely traffic jams or other flow problems.
223
+ Select a pallet from the combo box in the top-right. Once selected, all pallet cycles are displayed.
224
+ The x-axis is the days of the month and the y-axis is the pallet cycle time in minutes. A pallet
225
+ cycle time is the wall clock time from when a pallet leaves the load station to the next time it
226
+ leaves the load station. This will therefore include cart transfer time, buffer time, machining
227
+ time, and load/unload time. By clicking on a point, you can obtain more information about the pallet
228
+ cycle in a tooltip. Similarly to the station cycle chart, the pallet cycle chart can be zoomed by
229
+ clicking and dragging or the zoom range can be manually set via the button in the bottom-right.
230
+
231
+ The pallet cycle chart is best used to determine if the cell is running lean and validate the
232
+ [daily allocation and scheduling technique](https://www.seedtactics.com/docs/tactics/preventing-traffic-jams)
233
+ to determine if there are traffic jams occurring in the pallets. In a lean, healthy cell, most
234
+ pallet cycles should be low and reasonably consistent. If pallet cycle times vary wildly, there is
235
+ likely traffic jams or other flow problems.
266
236
 
267
237
  ## Cell
268
238
 
269
239
  #### Quality
270
240
 
271
- The quality shows all paths taken by parts through the system for each inspection.
272
- The inspections can be viewed either as a sankey diagram or as a table.
241
+ The quality shows all paths taken by parts through the system for each inspection. The inspections
242
+ can be viewed either as a sankey diagram or as a table.
273
243
 
274
244
  ![Screenshot of path sankey](screenshots/insight-quality-sankey.png)
275
245
 
276
246
  #### Tool Replacements
277
247
 
278
- The tool replacement chart shows data about tool replacements over the month. Each
279
- tool is shown with the number of replacements, average usage at replacement, and average
280
- count at replacement. These numbers are approximate if a tool replacement happens during
281
- a cycle, since we do not know the exact time of the replacement. Each tool also shows a graph
282
- of all replacements over the whole month, with the red line the average and a black dot for each
283
- replacement. A replacement can be hovered for more information.
248
+ The tool replacement chart shows data about tool replacements over the month. Each tool is shown
249
+ with the number of replacements, average usage at replacement, and average count at replacement.
250
+ These numbers are approximate if a tool replacement happens during a cycle, since we do not know the
251
+ exact time of the replacement. Each tool also shows a graph of all replacements over the whole
252
+ month, with the red line the average and a black dot for each replacement. A replacement can be
253
+ hovered for more information.
284
254
 
285
255
  ![Screenshot of tool replacements](screenshots/insight-tool-replacements.png)
286
256
 
287
257
  #### Schedules
288
258
 
289
- The schedules report shows all the scheduled jobs for the month, details about the schedule, and
290
- a list of all serials machined on the schedule.
259
+ The schedules report shows all the scheduled jobs for the month, details about the schedule, and a
260
+ list of all serials machined on the schedule.
291
261
 
292
262
  ![Screenshot of schedules](screenshots/insight-monthly-schedules.png)
293
263
 
294
264
  ## Cost/Piece
295
265
 
296
- Cost-per-piece is a great [metric](improve-fms) for scheduling, operations
297
- management, future capital purchases, quoting work, accounting, and
298
- budgeting. The cost/piece tab is largely intended to serve as a
299
- verification that flexibility and operational changes are reducing part
300
- costs; you can compare part costs from before a change to after a change to
301
- understand if the change improved the system.
302
- Indeed, FMS Insight has a narrow view of just the cell itself and does not
303
- take into account any overhead or other costs. Therefore, for budgeting,
304
- quoting work, and other management decisions, we suggest that you export the
305
- cost breakdown or workorder data to your ERP and implement
306
- a cost report in your ERP taking into account all factors.
307
-
308
- Cost/piece is not a great metric to use initially when searching for techniques
309
- to improve the cell's operation, since
310
- focusing only on cost/piece risks introducing quality problems and OEE
311
- reduction. Instead, cost/piece is a great metric to use after-the-fact to determine
312
- if an implemented change in production operations has had a meaningful impact on
313
- cost/piece.
266
+ Cost-per-piece is a great [metric](improve-fms) for scheduling, operations management, future
267
+ capital purchases, quoting work, accounting, and budgeting. The cost/piece tab is largely intended
268
+ to serve as a verification that flexibility and operational changes are reducing part costs; you can
269
+ compare part costs from before a change to after a change to understand if the change improved the
270
+ system. Indeed, FMS Insight has a narrow view of just the cell itself and does not take into account
271
+ any overhead or other costs. Therefore, for budgeting, quoting work, and other management decisions,
272
+ we suggest that you export the cost breakdown or workorder data to your ERP and implement a cost
273
+ report in your ERP taking into account all factors.
274
+
275
+ Cost/piece is not a great metric to use initially when searching for techniques to improve the
276
+ cell's operation, since focusing only on cost/piece risks introducing quality problems and OEE
277
+ reduction. Instead, cost/piece is a great metric to use after-the-fact to determine if an
278
+ implemented change in production operations has had a meaningful impact on cost/piece.
314
279
 
315
280
  #### Percentages
316
281
 
317
282
  Calculating cost-per-piece requires splitting large fixed costs such as machine depreciation and
318
- labor across the parts that were produced. To do so, we use a monthly analysis window of the
319
- actual operations together with the planned use of resources to determine a percentage breakdown
320
- of the cost for each part.
283
+ labor across the parts that were produced. To do so, we use a monthly analysis window of the actual
284
+ operations together with the planned use of resources to determine a percentage breakdown of the
285
+ cost for each part.
321
286
 
322
287
  ![Screenshot of cost breakdown table](screenshots/insight-cost-percentages.png)
323
288
 
324
- To do so, consider that the system produces two part types, aaa and bbb,
325
- and aaa has a planned cycle time of 3 hours and bbb has a planned cycle time of 2 hours.
326
- For January we collect data on the total number of parts produced by the system. Consider that
327
- in January the system produced 400 aaa parts and 500 bbb parts. We then calculate the cost breakdown
328
- as follows. Since we produced 400 aaa parts, those aaa parts should have used 400\*3 = 1200
329
- machine-hours. Similarly, the bbb parts should have used 500\*2 = 1000 hours. Thus, aaa used `1200 / (1000 + 1200) = 54.5%` of
330
- the planned hours and bbb used `1000 / (1000 + 1200) = 45.5%` of the planned hours.
331
- Similar calculations happen for labor and automation.
289
+ To do so, consider that the system produces two part types, aaa and bbb, and aaa has a planned cycle
290
+ time of 3 hours and bbb has a planned cycle time of 2 hours. For January we collect data on the
291
+ total number of parts produced by the system. Consider that in January the system produced 400 aaa
292
+ parts and 500 bbb parts. We then calculate the cost breakdown as follows. Since we produced 400 aaa
293
+ parts, those aaa parts should have used 400\*3 = 1200 machine-hours. Similarly, the bbb parts should
294
+ have used 500\*2 = 1000 hours. Thus, aaa used `1200 / (1000 + 1200) = 54.5%` of the planned hours
295
+ and bbb used `1000 / (1000 + 1200) = 45.5%` of the planned hours. Similar calculations happen for
296
+ labor and automation.
332
297
 
333
298
  From a cost perspective, any bottlenecks or utilization slowdowns should be viewed as system
334
- problems and all parts are responsible for a portion of this cost. Indeed, The cost-per-piece
335
- metric is an actionable insight for quoting orders and justifying future capital investments and for
336
- these purposes any OEE problems are a problem for everything produced by the system. The above
337
- method does this by using planned cycle times to divide the total machine cost (which includes
338
- active and idle time) among the parts produced during the month based on their weights. A quick
339
- calculation of machine utilization gives `(1200 + 1000) / (24*30*4) = 76%` use. The above method
340
- divides the 24% of the time the machine is not in use among aaa and bbb based on their percentages
341
- of planned use. Attempting to identify OEE problems are better addressed using the
342
- efficiency reports above.
299
+ problems and all parts are responsible for a portion of this cost. Indeed, The cost-per-piece metric
300
+ is an actionable insight for quoting orders and justifying future capital investments and for these
301
+ purposes any OEE problems are a problem for everything produced by the system. The above method does
302
+ this by using planned cycle times to divide the total machine cost (which includes active and idle
303
+ time) among the parts produced during the month based on their weights. A quick calculation of
304
+ machine utilization gives `(1200 + 1000) / (24*30*4) = 76%` use. The above method divides the 24% of
305
+ the time the machine is not in use among aaa and bbb based on their percentages of planned use.
306
+ Attempting to identify OEE problems are better addressed using the efficiency reports above.
343
307
 
344
308
  The data can be copied to the clipboard via the two-arrow-icon button in the top right.
345
309
 
346
310
  #### Part Cost/Piece
347
311
 
348
- Once the percentage breakdown for each part is calculated, the webpage allows you to
349
- enter the total machining, labor, and automation cost for the period. This value
350
- is then multiplied by the above cost breakdown percentages to get a total cost per
351
- piece. As mentioned above, we suggest that you copy the above cost breakdown percentages
352
- into your own spreadsheet or ERP system to be able to account for overhead, overtime,
353
- material costs, and other costs not visible to FMS Insight.
312
+ Once the percentage breakdown for each part is calculated, the webpage allows you to enter the total
313
+ machining, labor, and automation cost for the period. This value is then multiplied by the above
314
+ cost breakdown percentages to get a total cost per piece. As mentioned above, we suggest that you
315
+ copy the above cost breakdown percentages into your own spreadsheet or ERP system to be able to
316
+ account for overhead, overtime, material costs, and other costs not visible to FMS Insight.
354
317
 
355
318
  ![Screenshot of part cost/piece page](screenshots/insight-part-cost.png)