INTERNATIONAL STANDARD ISO 22400-2 First edition 2014-01-15 Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 2: Definitions and descriptions Systèmes d’automatisation et intégration — Indicateurs de la performance clé pour le management des opérations de fabrication — Partie 2: Définitions et descriptions Reference number ISO 22400-2:2014(E) ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST © ISO 2014 COPYRIGHT PROTECTED DOCUMENT © ISO 2014 All rights reserved Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior written permission Permission can be requested from either ISO at the address below or ISO’s member body in the country of the requester ISO copyright office Case postale 56 • CH-1211 Geneva 20 Tel + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyright@iso.org Web www.iso.org Published in Switzerland ii Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - ISO 22400-2:2014(E) ISO 22400-2:2014(E) Contents Page Foreword iv Introduction v 1 Scope Terms and definitions Symbols and abbreviated terms Structure of KPI description Elements used in KPI description 5.1 Time elements 5.2 Time model for work units 5.3 Time model for production order Time model for personnel 5.4 5.5 Logistical elements 5.6 Quality elements 11 5.7 Quality elements 11 Description of KPIs 12 7 Conformance 37 Annex A (normative) Effect models 38 Annex B (informative) Alternative OEE calculation based on loss time model 57 ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Bibliography 60 © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST iii ISO 22400-2:2014(E) ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies) The work of preparing International Standards is normally carried out through ISO technical committees Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization The procedures used to develop this document and those intended for its further maintenance are described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the different types of ISO documents should be noted. This document was drafted in accordance with the editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives). Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights ISO shall not be held responsible for identifying any or all such patent rights. Details of any patent rights identified during the development of the document will be in the Introduction and/or on the ISO list of patent declarations received (see www.iso.org/patents) Any trade name used in this document is information given for the convenience of users and does not constitute an endorsement For an explanation on the meaning of ISO specific terms and expressions related to conformity assessment, as well as information about ISO’s adherence to the WTO principles in the Technical Barriers to Trade (TBT) see the following URL: Foreword - Supplementary information The committee responsible for this document is Technical Committee ISO/TC 184, Automation systems and integration, Subcommittee SC 5, Interoperability, integration and architectures of automation systems and applications ISO 22400 consists of the following parts, under the general title Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 1: Overview, concepts and terminology — Part 2: Definitions and descriptions The following parts are under preparation: — Part 3: Exchange and use — Part 4: Relationships and dependencies iv Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Foreword ISO 22400-2:2014(E) Introduction This part of ISO 22400 focuses on key performance indicators (KPIs) for manufacturing operations management KPIs are defined as quantifiable and strategic measurements that reflect an enterprise’s critical success factors KPIs are very important for understanding and improving manufacturing performance, both from the lean manufacturing perspective of eliminating waste and from the corporate perspective of achieving strategic goals Manufacturing operations management (MOM) is a term used in IEC 62264 to specify a portion of the functional hierarchy model of a manufacturing enterprise Figure 1 depicts the different levels of the functional hierarchy model: business planning and logistics (Level 4), manufacturing operations and control (Level 3), and batch, continuous, or discrete control (Level 1-2) The levels provide different functions and work in different timeframes Adapted from IEC 62264-3 Figure 1 — Functional hierarchy IEC 62264 also specifies a hierarchical structure for the physical equipment (see Figure 2) Enterprise, site and areas are generic terms, whereas there are specific terms for work centres and work units that apply to batch production, continuous production, discrete or repetitive production, and for storage and movement of materials and equipment © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST v ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - NOTE ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - ISO 22400-2:2014(E) NOTE Adapted from IEC 62264-3 Figure 2 — Role based equipment hierarchy This part of ISO 22400 specifies the KPIs “residing” at Level 3, i.e related to MOM These KPIs are generated/calculated within Level Some of these KPIs are forwarded to Level for further usage In order to generate these KPIs, parameters from Levels and might be needed The KPIs in this part of ISO 22400 use the most generic terms possible (e.g work centres and work units), instead of industry specific terms MOM, sometimes referred to as manufacturing execution systems (MES), models four major categories of operations management: — production operations management; — maintenance operations management; — quality operations management; — inventory operations management An activity model further details each category Each activity model includes eight activities: — detailed scheduling; — dispatching; — execution management; — resource management; — definition management; — tracking; vi Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) — data collection; — analysis These activities apply to production operations, quality operations, inventory operations and maintenance operations Analysis is the performance of calculating KPIs using information from other activities Workflows can be used to illustrate the important events and steps needed in the calculation process for KPIs KPIs alone are not sufficient factors to perform the necessary management and execution operations for an enterprise For many of the indicators, a company specific threshold is defined When the value of the indicator exceeds or falls below the threshold, actions are initiated (e.g to improve efficiency or quality) Often it is necessary to define warning and action limits Warning limits help to detect the trends in process and equipment changes before company-specific thresholds are violated To improve the productivity of the manufacturing resources, information provided by industrial automation systems and control devices about process, equipment, operator, and material can be useful for providing critical feedback through KPIs A standardized schema for the expression of these KPIs is intended to: a) facilitate the specification and procurement of integrated systems, in particular, the interoperability requirements among MES applications; b) provide a means to categorize productivity tools that can be used across applications ISO 22400 provides an overview of the concepts, the terminology and the methods to describe and to exchange KPIs for the purpose of managing manufacturing operations The audience is factory managers responsible for production performance, software suppliers developing KPIs for factory management, engineers engaged in process planning of products, planners and designers of manufacturing systems, and equipment and device suppliers KPIs also reside at Level 4, i.e KPIs related to business planning and logistics, which are outside the scope of this part of ISO 22400 Level KPIs are often related to economic, business, logistic and financial factors These KPIs are used to assess the progress or extent of compliance with regard to important objectives or critical success factors within a company Economic KPIs serve as a basis for decisions (problem identification, presentation, information extraction), for economic control (target/actual comparison), for financial documentation and for coordination (behaviour management) of important facts and relationships within the company ```,``,,,``,``,,, © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST vii ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST INTERNATIONAL STANDARD ISO 22400-2:2014(E) Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 2: Definitions and descriptions 1 Scope ISO 22400 specifies key performance indicators (KPIs) used in manufacturing operations management (MOM) This part of ISO 22400 specifies a selected number of KPIs in current practice The KPIs are presented by means of their formula and corresponding elements, their time behaviour, their unit/dimension and other characteristics This part of ISO 22400 also indicates the user group where the KPIs are used, and the production methodology to which they correspond Terms and definitions For the purposes of this document, the following terms and definitions apply ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - With reference to equipment, the KPIs in this part of ISO 22400 relate to work units, as specified in IEC 62264 2.1 reference time base timeline used for time models, corresponding to the planned maximum time interval available for production and maintenance tasks EXAMPLE A calendar day with 24 hours; a week EXAMPLE The intended duration of an operation or a resource state according to the planning EXAMPLE The actual duration of an operation or a resource state 2.2 planned time planned duration of a specific time period 2.3 actual time realized duration of a specific time period Note 1 to entry: Actual time may be less than, equal to, or greater than corresponding planned time 2.4 time model partition of the reference time Symbols and abbreviated terms ADET actual unit delay time © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) ADOT actual unit downtime APAT actual personnel attendance time AOET actual order execution time APT actual production time APWT actual personnel work time AQT actual queuing time AUST actual unit setup time ATT actual transport time AUBT actual unit busy time AUPT actual unit processing time CI consumables inventory Cm machine capability index CM consumed material Cmk critical machine capability index CMT corrective maintenance time Cp process capability index Cpk critical process capability index EPC equipment production capacity FE failure event FGI finished goods inventory GP good part GQ good quantity IGQ integrated good quantity IP LT MOM NEE NOT OC OEE OL 2 ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - LSL inspected part lower specification limit loading time manufacturing operations management net overall equipment effectiveness index net operating time operation cluster overall equipment effectiveness other loss Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Figure A.15 — First pass yield ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - 48 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Figure A.16 — Scrap ratio © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Figure A.17 — Rework ratio Figure A.18 — Fall-off ratio ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 49 ISO 22400-2:2014(E) Figure A.19 — Machine capability index and critical machine capability index Figure A.20 — Process capability index and critical process capability index ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - 50 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Figure A.21 — Comprehensive energy consumption ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Figure A.22 — Inventory turns © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 51 ISO 22400-2:2014(E) Figure A.23 — Finished goods ratio Figure A.24 — Integrated goods ratio ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - 52 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Figure A.25 — Production loss ratio Figure A.26 — Storage and transportation loss ratio © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 53 ISO 22400-2:2014(E) Figure A.27 — Other loss ratio Figure A.28 — Equipment load ratio 54 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Figure A.29 — Mean operating time between failures ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Figure A.30 — Mean time to failure © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 55 ISO 22400-2:2014(E) Figure A.31 — Mean time to repair ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Figure A.32 — Corrective maintenance ratio 56 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Annex B (informative) Alternative OEE calculation based on loss time model B.1 General This annex could be used to calculate the OEE (overall equipment efficiency) based on partitioning of the total time, e.g amount of loss time for operation NOTE Annex B provides a time model for work units with different time element partitions for which KPIs (e.g OEE) generated using that model are different from those specified in Clause 6 B.2 Time model for work units Figure B.1 is the time model for calculation the OEE ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Figure B.1 — Time model for calculation of the OEE B.3 KPIs Tables B.1 to B.3 give KPIs © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 57 ISO 22400-2:2014(E) Table B.1 — Overall equipment effectiveness index KPI description Content Name Overall equipment effectiveness index Description The OEE index represents the availability of a work unit, the effectiveness of the work unit, and the finished goods ratio integrated in a single indicator Formula OEE index = Availability * Performance rate * Finished goods ratio ID Scope Unit of measure Range Work unit, product, defect type % Min: 0% Max: 100% Trend Context The higher, the better Timing On-demand, periodically Production methodology Batch, continuous Audience Effect model diagram Notes Supervisor, management Overall equipment effectiveness (OEE) is a measure for the efficiency of machines and/ or plants, manufacturing cells with several machines or an entire assembly line The OEE index forms the basis for improvements by better production information, identification of production losses, and improvement of the product quality by optimized processes The OEE index represents the used availability, the effectiveness of the work unit, and their finished goods rate summarized in a characteristic number With the bench mark of manufacturing processes by means of the OEE index the criteria for comparability are to be examined before The indicator finished goods ratio is specified in Table 26 Table B.2 — Availability KPI description Content Name Availability Description Availability indicates the proportion of time the equipment is actually utilized (OPT) against the loading time (LT) The availability represents the magnitude of equipment stoppage loss ID Scope Work unit Formula Unit of measure Range Availability = OPT / LT % Min: 0% Max: 100% Trend Context The higher, the better Timing On-demand, periodically Production methodology Batch, continuous Audience Effect model diagram Notes ```,``,,,``,``,,,,``````````, 58 Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Supervisor, management The term availability is also called usage grade © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ISO 22400-2:2014(E) Table B.3 — Performance ratio KPI description Content Name Performance ratio Description The performance ratio relates the net operating time (NOT) to the operating time (OPT) Formula Performance ratio = NOT / OPT ID Scope Work unit, product, production order Unit of measure % Range Min: 0% Max: 100% The 100% can be exceeded, if the planned production time for each work unit is larger than the actual production time Trend Context The higher, the better Timing On-demand, periodically, real-time Production methodology Batch, continuous Audience Effect model diagram Notes Operator, supervisor, management Performance rate is the measure for the performance of a process The gap of the target cycle time and the actual cycle time is represented This gap represents the speed loss The performance rate is a characteristic number that can be calculated and displayed in short periodic distances at run time of a machine Performance rate is also called efficiency factor or performance ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST 59 ISO 22400-2:2014(E) Bibliography [1] ISO 13053-1, Quantitative methods in process improvement — Six Sigma — Part 1: DMAIC methodology [3] ISO 22400-1, Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 1: Overview, concepts and terminology [2] ISO 13053-2, Quantitative methods in process improvement — Six Sigma — Part 2: Tools and techniques [4] IEC 60050-191, International Electrotechnical Vocabulary — Chapter 191: Dependability and quality of service [6] IEC 62264-3, Enterprise-control system integration — Part 3: Activity models of manufacturing operations [8] IEC 80000 (all parts), Quantities and units [5] [7] [9] [10] 60 IEC 62264-1, Enterprise-control system integration — Part 1: Models and terminology ISO 80000 (all parts), Quantities and units VDMA, Association of German Machinery and Equipment Manufacturers, KPI standard sheets DIN NA 060-30-05-03, Definition of MES and Quality Management Requirements on MES Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - © ISO 2014 – All rights reserved Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST ```,``,,,``,``,,,,``````````,,-`-`,,`,,`,`,,` - ISO 22400-2:2014(E) ICS 25.040.01 Price based on 60 pages © ISO 2014 – All rights reserved Copyright International Organization for Standardization Provided by IHS under license with ISO No reproduction or networking permitted without license from IHS Licensee=University of Alberta/5966844001, User=ahmadi, rozita Not for Resale, 12/26/2014 14:43:19 MST