Production Tracking
Measure and report production output per station, per SKU.
It goes without saying, production output is fundamental to any manufacturing operation.
Busroot can track production in 1 of 3 ways:
Direct sensing of produced units from a machine signal (i.e. light gate or actuator).
Inferred production output from a measured speed or rate (i.e. conveyor speed or motor energy consumption).
Production declared manually by operators via a tablet interface.
Busroot will reference the current production schedule of the station to understand the SKU produced. If a production schedule is not available, it will be tracked under a special 'UNKNOWN' SKU code. To understand more about how production scheduling works, please see the Scheduling section.
Production Quality
Busroot is capable of also tracking bad production. This allows for accurate output tracking and cycle time analysis, while being able to exclude these production counts from reports and calculate OEE quality.
Batch Counts
It is possible to configure at a SKU level a batch size that acts as a multiplier for production complete signal. This allows for the batch size to change based on which product is being produced.
Tablet operators will be told the batch size via the interface.
If a batch count has been added. Busroot will count 1 signal from the machine and display this as the batch count in your Busroot account. So, if you have a batch count of 12. Every time Busroot receives a production count signal from the machine 12 will be counted and displayed in Busroot.
Production Reporting
Production counts can be retrieved in various ways through the user interface:
By Station
By SKU
Weekly Production counts.
Or downloaded in CSV format, or retrieved via the API.
Using the production progress dashboard to understand real-time progress against production targets.
Benefit
Allows operators and production managers to visualise in real time, the current progress of a schedule against where they should be.
Setup
Each station to be monitored must have a production schedule. This can be created via Schedule Management page or Quick Schedule Start.
All SKUs to be produced must have a Performance Target set. This is the ideal rate that the SKU should be produced, based on Cycle Time, Units per Minute, Units per Hour or an Independent Process Speed.
TV screens installed on shop floor and a tablet for each station to be monitored.
Daily Workflow
Production manager adds schedules for the day. Or an operator can create a Quick Schedule on the tablet.
Operator starts a schedule on tablet.
Production count can be recorded directly from the machine or manually entered via Operator Tablet.
Schedules will appear on Production Progress Chart displaying the current quantity completed, whether the schedule is currently on target and an estimated time remaining.
If necessary Performance Targets can be refined to consider whats happening on the shop floor.
How can I configure inferred production counts from a process speed or rate?
First, the process speed or rate should be fed into Busroot via the speed signal.
Next, for that station a 'Speed to Production Ratio' should be configured. Any speed signals received during a 1 minute window will be averaged and then multiplied by this ratio to give the production quantity for that 1 minute window.
e.g. if sensor can detect a line's movement speed with a value between 0 and 1 (1 being full speed, 0 being stopped), and we know at full speed the line is moving at 10 meters per minute, we can set a 'Speed to Production Ratio' of 10. Now, if the line continually moved at full speed, the average speed will be 1, and Busroot will record a production quantity of 10.
If the speed is negative, production quantity will always be 0.
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