Machine Operators interact with MachineMetrics through a tablet PC that is assigned to and located at each machine on your factory floor that is connected to MachineMetrics. Through the Newest version of the Operator Dashboard, or Operator Dashboard 2.0, Operators add contextual data about downtime, alarms, quality, and more. This data can then be used to run reports and to create improvement plans that will increase the production and efficiency of your operations.
Note: This article explores the anatomy and functionality of the Operator Dashboard 2.0. To learn about the legacy Operator Dashboard (Operator Dashboard 1.0), visit this article.
This article covers the following topics:
- Accessing the Operator Tablet Interface View
- Op Dash Anatomy
- The Tabs
- How To's
Accessing the Operator Dashboard
Currently, the Operator Dashboard 2.0 must be enabled by a MachineMetrics team member. If you have the Operator Dashboard 2.0 implemented on your machines, you will simply follow the instructions as follows to access it for any individual machine. If you do not and would like to enable the Operator Dashboard 2.0, reach out to Support@machinemetrics.com or contact your Customer Success Manager.
- Login to MachineMetrics.
- From any Current Shift Dashboard view, click on the tile for the machine that you want to view.
- The machine tile will change to display several icons. To change to the operator tablet interface view, click the expansion arrow icon in the bottom right of the tile as highlighted below:
- The operator tablet interface view will display
Op Dash Anatomy
The Op Dash contains a lot of useful information for Operators running the machines. Additionally, it can be a useful tool for managers, providing a fast way to check in on different machines on the factory floor.
This section will take you through the anatomy of the Op Dash, including the following:
- Machine Operating Status: a color guide
- The Tabs: location and list
- Performance Wheel: Part Count and Utilization
- Navigation: Button Bar variations
1. Machine Operating Status
The top of the operator tablet interface displays the machine operating status (in text and colored bar) with a time counter indicating the length of time the machine has been at that status. See below for a visual of where on the tablet the operating status can be found along with a color guide.
2. The Tabs
As you move below the color bar at the top of the Op Dash, you will notice a set of Tabs. Tabs offer a way for the Operator to move around the tablet to different parts of the interface. After we finish with the anatomy, we will take an in-depth look at each tab.
The following is a list of Tabs included in the default view of the Operator Dashboard:
- Part Count
- All Downtime
- Active Alarms
- Parts Goal
- Current Cycle Time
3. Performance Wheel
The Performance Wheel may look familiar to you because it is primarily the same as on the Operator Dashboard 1.0. The Performance Wheel offers information on how the machines are performing compared to the thresholds you set up in your Settings.
As shown below, the ring of the Performance Wheel represents the "Scope of Time." The Scope of Time runs from the beginning of a Shift, Setup, or Job, until the end of the shift.
Note: End of Scope may differ if you schedule your Jobs since Scheduled Jobs have a definitive end time.
Below we outline the general anatomy of the Performance Wheels. We will cover these in more detail in The Tabs section below.
The bottom section of the Operator Dashboard is the Navigation Button Bar. The Navigation Button Bar reflects how your company is configured in MachineMetrics. Depending on if you run jobs or not, as well as if you use Autojob Dispatch or track quality, your Button Bar will vary as shown in the variations chart below:
1. Part Count: An Overview of Parts Made
The Part Count Tab shows how many parts have been made compared to how many parts should have been made by this time. We use Expected Part Count to calculate how many parts should have been made by a particular time.
The Performance Wheel gives a quick visual overview of how the machine is tracking compared to the expected performance.
Parts Performance Goals determine the color of the Performance Wheel on this tab.
The Goal thresholds can be set up on the System Settings level, the Machine Level, or the Job Level. The most specific goals set up will override the others. For example, Job Utilization Goals will override those goals configured in Machine and System Settings. Performance Thresholds set up in System Settings are the default, and if no others are configured, will control the colors on the performance wheels.
How Operators are using this tab: We have found that on average, the Operator will spend the most time on this tab unless the company's focus is primarily Utilization, in which case, they typically hang out on the Utilization Tab for the majority of the time.
2. Utilization: Track the percentage of time a machine is in-cycle
The Utilization tab on the Op Dash displays the average Utilization percentage for the machine since the start of the current shift. You can see from the performance ring in the middle of this dashboard, this machine is at 96% Utilization, which means it has been in-cycle 96% of the time during the current shift.
Utilization Goals determine the color of the Performance Wheel on this tab.
The Goal thresholds can be set up on the System Settings level, the Machine Level, or the Job Level. The most specific goals set up will override the others. For example, Job Utilization Goals will override those goals configured in Machine and System Settings.
3. All Downtime: Find and categorize all downtime events in one place
The All Downtime Tab offers visibility of all downtime events. The Operator can search as well as filter the list of events by Status, Type, and Time.
How operators are using this Tab: Operators have reported using the All Downtime Tab as a way to see Downtime Events from the previous shift to understand the status of things better coming into their own shift.
4. Active Alarms: A history of all Active Alarms
The Active Alarms Tab offers a history of Active Alarms that have occurred on a machine. The Operator can search as well as filter the list of events by Status, Date, and Severity.
How operators are using this Tab: Like with the All Downtime tab, Operators have reported using the Active Alarms Tab to better understand what happened in previous shifts.
5. Parts Goal: Track Actual Parts compared to Expected Parts
Parts Goal is a metric that compares the number of parts actually made to the number of parts that should have been made within a time period. We use the Expected Part Rate to determine the number of parts that should be produced within an hour.
How is Expected Part Rate calculated?
Expected Part Rate is set up in the Job Performance Standards and reflects the total time expected for processing the parts, including machine setup, teardown, and setup for the next part, also known as "button-to-button" production time. Job Performance Goals, like Parts Goal, show how close you are to the Expected Part Rate.
Note: It is best practice to use data from MachineMetrics to validate and update your job standards over time.
How operators are using this tab: Some customers have reported Operators using this Tab as a way of monitoring program performance. One Operator mentioned adjusting a program and referencing this burn up chart to see if the change was making a positive impact on the Parts Goal.
6. Cycle Time: Track how much time has been spent in-cycle
Current Cycle Time is a metric that indicates the amount of time spent in the current cycle on this Machine.
Note: A Cycle is determined by how your Machine counts Parts and also by the way your organization's System Settings are configured. To learn more, visit this article in our Knowledge Base.
6. OEE: Measure Productivity
OEE (Overall Equipment Effectiveness) is the manufacturing standard for measuring manufacturing productivity. It identifies the percentage of manufacturing time that is truly productive.
Let's take a closer look at the metrics that make up this calculation:
Availability takes into account Unplanned and Planned Downtime. An Availability score of 100% means the process is always running during Planned Production Time.
Performance takes into account Slow Cycles and Small Stops. A Performance score of 100% means when the process is running it is running as fast as possible.
Quality takes into account Rejected Parts (including parts that need Rework). A Quality Score of 100% means there are no Rejects (only Good Parts are being produced).
Overall Equipment Effectiveness
OEE takes into account all losses. An OEE score of 100% means you are manufacturing only Good Parts, as fast as possible, with no Stop Time.
Want to learn more?
Op Dash How To's
For those Operators that do sign in, they will select Sign In under the Performance Wheel. This will open a screen with all Operators listed. After selecting their user from the list, the Operator name will now appear under the Performance Wheel.
Note: Typically, when an Operator signs in, it will ask if they would like to sign in at the Start of Shift or Now as shown below.
However, if another user has signed in since the start of the shift, the Operator will see the option to log in at Last Sign Out or Now as shown below:
To sign out, an Operator can select the pop-up menu located in the bottom left corner, and select Sign Out as shown below:
There may be times when an Operator is signed in and another Operator gets to the machine and needs to switch to his/her own operator account. When this happens, the Operator can follow the process outlined below to Switch Users.
An Operator can switch machines from the Op Dash using the menu at the bottom left, as shown below:
Understanding the main reasons why machines are down, particularly why they go down unexpectedly, is critical for companies that want to reduce the impact of downtime on their manufacturing operations.
This section will go through the different ways downtime can be categorized using the Op Dash, including:
- Categorizing a Current Downtime Event
- On-demand Categorization of Downtime
- Using the All Downtime Tab to Categorize Downtime
- Retroactively Categorizing Downtime
Categorizing a Current Downtime Event
A current downtime event will show in a pop-up in the bottom right of the tablet interface and will prompt the Operator to address it immediately, as shown below.
On-Demand Categorization of Downtime
On the image above, you will notice the Categorize button within the Navigation Bar that has a Red Bubble with a number in it. This is how an Operator can categorize downtime on-demand from any tab. Once selecting Categorize from the navigation button bar, the Operator will be taken through the categorize flow.
Using the All Downtime Tab to Categorize Downtime
The All Downtime Tab is a great place to see all Downtime Events for a shift and categorize them right from the tab.
As you can see below, this tab will show Operators the status of the downtime events, so they can easily select the events that are uncategorized.
The Categorizing Downtime Flow on the Tablet
Above we have listed a few ways Operators can categorize downtime at the machine. Each of these options will take the Operator through the appropriate categorization flow.
Below you will find a visual of how this flow works:
Retroactively Categorizing Downtime
Although it is a best practice that Operators categorize downtime at the time it occurs, there may be downtime events that do not get categorized by the Operators. In these scenarios, Executive and Manager users as well as operators can categorize downtime in the operator tablet interface after the event has occurred.
Executive and manager users can also categorize downtime after the event in the Timelines Dashboard.
Starting & Stopping Jobs
If your Company tracks Jobs, you will see the following navigation options on the button bar, shown in the image below.
Auto-Job is On means that you use Auto-Job Dispatch, and jobs are automatically started and stopped by a integration with your ERP.
If you do not use Auto-Job Dispatch, you will see the option to Select Job or Stop Job, as shown below.
Starting a Job in Setup
Note: The Op Dash 2.0 currently does not support Setup Stages. If your company tracks Setup Stages, you will need to continue using the legacy version of the Operator Dashboard for the time being.
Note: You will only have the option to Start a Job in Setup if your Company tracks planned and unplanned Setup.
Tracking setup allows you to gain more insight into how setup times are effecting your factory production. Configuring planned setup times in your Job settings allows you to notify your Operators if they go beyond what is expected for setup time on a specific Job.
Fun Fact: Planned Setup is automatically categorized as Planned Downtime, and Unplanned Setup, or time spent in setup beyond what has been estimated, is categorized as Unplanned Downtime.
Below, the Start in Setup process has been outlined, including the ability to input scrapped parts from the time spent in setup.
Parts can be rejected at the machine by an Operator or after a Job is complete by the Quality Management Team, depending on your business operations. This section will cover how and when an Operator can Reject Parts at the tablet.
Note: If your company does not track quality, this section may not be useful.
Rejecting Parts during a Job Run
At any time, and from any tab, an Operator can select Reject Parts from the navigation button bar.
The Reject Parts Flow
Below, the process for rejecting parts is outlined. Learn more about configuring your Reject Reasons here.
Rejecting Parts during Setup
If your company tracks Setup, your Operators may have rejects that occur during the setup process. See this section on Setup to learn more.
Using Operator Input Data
To learn more about how to explore and use the Operator Input Data, visit this article.
Reach out to Support@machinemetrics.com if you have additional questions, or if you would like to enable Operator Dashboard 2.0 on your machines.