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General

1.1 Priority: Medium

1.2 Phase tracking and assignments


FD prepared by Venkat paluri
FD reviewed by Venkat paluri
Signed off by Venkat paluri
User contact Mr Nagendra.H

1.3 Version/Issue history

Version/Issue Date Created/Changed Changes made


No by
1.0 Venkat paluri FD preparation started
1.0 Venkat paluri Completed preparing FD
1.1 Venkat paluri Additional logic added for available capacity
calculation
2 Venkat paluri Option for IDLE time report to be generated

2.Functional specifications

2.1 Development Identification

Process group: ZOPM


Sub process group:
Description of the program: Overall equipment effectiveness

2.2 Business process

Overall equipment effectiveness consists of the following three parameter


1) Equipment availability = Actual usage(Hrs)/Planned usage(hrs)
2) Equipment performance = Theoretical cycle time for prodn (sec)*quantity produced/Actual usage
3) Quality= Quantity accepted/Qty produced

In order to arrive at the above values the report spans across PM---PP----QM modules

Comments as per 1.1


Initially it was assumed that the available capacity per day would be maintained in MRMAX field of
measurement point. The reason for this revision is that if there is any change, then the old data as analyzed
by this report will reflect the new available hrs even for older dates, which can be misleading. End of
comment 1.1

2.3 AS IS business flow diagram is not available.


NA

2.4 To be business process


NA
2.5 To be business process flow diagram(process logic)
NA
2.6 Audit and control requirements
Simple or interactive :NA
Output :Report as per the format
Frequency :Daily
Transaction volume :High
Processing type :Foreground with printing/Transfer to excel
Initial process :Entry of idle time data
Initiating program/Tcode : ---

3.Design data
3.1 Selection screen –Input fields

Equipment no from ---to EQUNR_low to EQUNR high


From date to date “DATE LOW TO DATE HIGH”
Radio button in one group

OEE
Idle time

If the above options idle time is selected, then the possibility of executing the CODE in section “3.2.4”
alone to be incorporated.

The dates have to be always less than or equal to previous day only, no where current dates data can be
handled.

Selection screen limitation, validation and authorization :Yes

3.2 Condition logic

tables used
EQUZ :Equipment time segment
EQKT :Equipment short texts
EQUI :Equipment master data

ILOA :PM object location and account assignment


IMPTT :Measuring point table
IMRG :Measurement document

S025 :SFIS: Run schedule


QALS :Inspection lot record
MKAL :Production version of material

PLKO :Task list header


PLPO :Task list operation/Activity
CRHD :Work center header
MAKT :Material description
KAKO :Capacity header segment
CRCA :Work center capacity allocation

KAPA :Shift parameter for available capacity


CRTX :Text for the work center or PRT
QPGR :Inspection catalog code group

QPCD :Inspection catalog codes

Logic

3.2.1 A)Actual quantity


Use EQUNR to select EQKTX from EQKT (This is equipment description)

Based on the equipment number EQUNR select ILOAN from EQUZ (This gives id of location assignment)

Use ILOAN to select PPSID from ILOAN (This gives the object ID of the production work center to which
the machine belongs)

At this point, if PPSID is blank Generate an output message indicating that “EQPT has no linkage to
production and exit the processing.

Use PPSID to select ARBPL from CRHD (This gives the work center for work center ID)

Use PPSID as OBJID to select KTEXT_UP from CRTX (This gives the description of work center)

Use ARBPL as MDV01,DATE_LOW to DATE_HIGH as SPTAG from S025 to get the following S025-
MATNR,S025-VERID,S025-Werks,S025-WEMNG (This will give the qty of material produced per day,
Mat no, version and plant)

Select MAKTG from MAKT for MATNR

Use MATNR,WERKS, and VERID, select PLNTY,PLNNR,ALNAL from MKAL (This gives the rate
routing used for above production , its type, group no and group counter no)

Use PLNTY,PLNNR,ALNAL as PLNKN, select LAR01-06,VGW01-06,VGE01-06 from PLPO (This gives


the std times for production of a component, also called as cycle time)
Out of 6 sets of fields LAR01 ….6 only one of them will have value =”MACH”, we have to pick up fields
and its VGEXX and VGWXX values.

The above will give the following qty of material produced (QA) per day per equipment and the cycle
time for production (TCT)

3.2.2 B) Rejected Qty


Using MATNR, select LMENGE04 from QALS where DATE_LOW <=ENSTEHDAT <=DATE_HIGH
and ART=PC (This gives the multiple lines with qty rejected for production related lots)
If QALS-LMENGEZUB is not equal to zero for any of the lines ,raise a warning message with “inspection
not yet complete for some of the lots”, the calculated of OEE may not be realistic.

Info:
“QALS_LMENGEZUB records the actual qty to be inspected unless it is zero, the lot has not been
inspected fully”
Sum up qty rejected for material per day.
This give us rejected quantity (QR)

3.2.3 C) Calculation of available capacity

Using PPSID as OBJID select KAPID from CRCA (This gives the capacity Ids of the capacities for the
work center
Using KAPID select KAPAR from KAKO. (This is to be done for each line selected from CRCA)

Check weather any of the selected lines has KAPAR=001 (This means the capacity is a machine capacity)

In case there are no entries that match the above condition, raise exception work center does not have
machine capacity, the calculation of OEE cannot continue and quits.

If there is KAPID where KAPAR = 001 then Using KAPID select DATUB,KAPAZ from KAPA (There may
be multiple lines here based on the capacity changes)
The available capacity AV_CAP is equal to KAPAZ where the date lies between dates in DATUB.

In case ANZHL is other than 1, Raise warning message with the following text “Work center capacities are
more than 1,Please check and rectify the situation, otherwise OEE calculation may not be realistic.”
Ex:
Data browser :Table KAPA select entries (This is SAP screen)

MANDT KAPID VERSN DATUB TAGNR SCHNR ANZHL BEGZT EINZT ENDZT FABTG KAPAZ PAUSE NGRAD
100 1000088 1 03.05.2004 1 1 3 28,800 27000 61200 81000 5400 100
100 1000088 1 10.05.2004 1 1 10 28,000 24300 61200 243000 5400 90
100 1000088 1 01.06.2004 1 1 3 28,000 27000 61200 81000 5400 100

The available capacity for 02-may-04 is 81000


Where as the available capacity for 6th may 04 is 24300 “since from 4th may to 10th may KAPAZ=243000

This gives AV_CAP


*****End of additions as per revision 1.1****

3.2.4 D) Idle time analysis

Using EQUNR select OBJNR from EQUI (This gives the object number for equipment)

Using OBJNR select POINT,INACT from IMPTT, where MPTYP = “I” and INACT = (This gives the
measurement point defined for idle time, Max operation time per day and the status of the point)
If there is more than 1 lines raise exception ,”more than 1 measurement point for monitoring idle time are
being used, Please correct this by making one of the point as inactive . OEE cannot be calculated as of now
and quit the processing.

Using POINT select MDOCM,IDATE from IMRG where DATE_LOW<IDATE<DATE_HIGH (This gives
the measurement document and their readings for the selection screen dates)

Using MDOCM , select IDATE,CDIFF,CODCT,CODGR and VLCOD from IMRG. (At this point the
selection may output multiple lines, these have to be stored in a temp table for consolidation as follows)

Explanation:
VLCOD contain values of following type A*,B*,C* where * means any xxx indicated codes.
The values in CDIFF have to be total against each of the three type given above per each day of analysis

This results in total CDIFF for VLCOD =Axxx etc

Info: The values in CDIFF are stored in floating point format ,they have to be converted to normal numbers
while generating the report output.

These values are to be stored in an internal table

Ex: POINT IDATE Axxx Bxxx Cxxx


200 24.04.04 15 250 35

Now Equipment availability factor is calculated as follows

Planned loading time T1= AC_CAP-Bxxx


Actual loading time T2 = T1-Axxx-Cxxx

Equipment availability EA is T2/T1 in NN.NN% format

Eqpt Performance EP= QA*TCT/T2


Eqpt quality EE=(QA-QR)/QA in NN.NN % format

Report Layout
Date 1st day

Eqpt code Eqpt Material Qty produced Qty Planned Act TCT Availability Performance Quality OEE
text no rejected hrs hrs EA*EP*EE
EQUNR 1 EQKTX MATNR WEMNG QR T1 T2 TCT EA EP EE
EQUNR 2 EQKTX MATNR WEMNG QR T1 T2 TCT EA EP EE
EQUNR 3 EQKTX MATNR WEMNG QR T1 T2 TCT EA EP EE
EQUNR 4 EQKTX MATNR WEMNG QR T1 T2 TCT EA EP EE

Date 2nd day


Same as above

Hidden fields- all other fields selected during the processing.


3.3 Security requirements

3.4 Authorizations :since it is a report for analysis of PM/PP/QM data, user who belong t shopfloor need to
be given this authorization to execute the print

3.5 Others
Indicate other security aspects if there is any

3.6 FORM

Menu transaction: ZPMOEE

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