OEE and losses on stamping and welding lines
The counters of presses and welding cells become OEE shift by shift and the six big losses, computed every morning by a function your team writes. When a press slows down after a die change, the dashboard colours it before the week is lost.
Illustrative scenario: it describes a typical case, not a customer project.
OEE shows up at month end. The press started slowing down three weeks earlier.
In an automotive parts plant, transfer presses and welding cells count everything: strokes, good parts, stops and their cause. The number management looks at, OEE, still comes from a spreadsheet rebuilt at month end, when a loss has already turned into a late delivery.
The problem is not the data, it is the time it takes to read it. A die change that adds micro-stops at every shift start costs a few minutes an hour, enough to take nine OEE points from a press without anyone noticing in time.
Muvia has no packaged OEE module. Your team writes the calculation once, in a Python function: Muvia runs it every morning next to the data and brings the result to the people who decide.
- Who it's for
- Plant managers, production and maintenance managers, process engineers at Tier 1 and Tier 2 suppliers.
In Muvia, step by step
Real product screens, recorded on a project with sample data.
The video · The counters of presses and welding cells become OEE shift by shift and the six big losses, computed every morning by a function your team writes. When a press slows down after a die change, the dashboard colours it before the week is lost.
What you get
- A loss shows in the week it starts
- A press that slows down after a die change changes colour on the dashboard the next day, not at month end.
- One definition of OEE
- The calculation lives in one function: the same for every press, cell and shift, and anyone can read it.
- The cause, not just the number
- Micro-stops per hour and the Pareto of causes say where to act, for example on pre-heating the die.
- The floor sees what management sees
- The same dashboard on the line's TV and in the meeting room: one version of the numbers.
For the technical team
How it is built in Muvia
- 1
Connect presses and cells
On the edge node you configure the S7 and OPC UA drivers and pick the variables: stroke counter, machine state, stop code. The MES arrives as a SQL Server source, copied on a schedule.
- 2
Write the calculation once
A Python function computes availability, performance and quality per machine and shift and assigns every lost minute to one of the six big losses. A flow runs it every morning at 5:30 and updates two tables.
- 3
Find where it stops
In Analysis the day-by-hour map of micro-stops shows the pattern: rows that light up at every shift start from a given date, next to the twin press.
- 4
Take it to the shop floor
The plant dashboard brings together OEE per shift, losses and the Pareto of causes; screen mode shows it on the shop-floor TV and refreshes by itself.
Python function
import pandas as pd
def transform(inputs, params, ctx):
p = inputs["rows"] # production hour by hour
g = p.groupby(["machine", "day", "shift"]).agg(
planned_min=("planned_min", "sum"),
stopped_min=("stopped_min", "sum"),
parts=("parts", "sum"),
good=("good_parts", "sum"),
cycle_s=("ideal_cycle_s", "mean"))
running = g["planned_min"] - g["stopped_min"]
g["availability"] = running / g["planned_min"]
g["performance"] = (g["parts"] * g["cycle_s"] / 60) / running
g["quality"] = g["good"] / g["parts"]
g["oee"] = g["availability"] * g["performance"] * g["quality"]
return {"rows": g.reset_index()}- The data it needs
- Stroke counters, state and stops of the presses from Siemens S7 PLCs
- Cycles and alarms of the welding cells over OPC UA
- Orders, ideal cycle times and shifts from the MES, copied from SQL Server
- The stop log with the cause the operator picked
More cases in this line
All use cases- The critical dimension that drifts before the first scrapMeasurements of critical characteristics become a control chart with the Western Electric rules and Cpk per die and per week. Die wear shows when Cpk falls below the target, while no part is out of tolerance yet.
- Process quality and traceabilityProcess parameters from the PLC, lots from the line database, orders and scrap from the ERP, all in the same engine. Every lot has its process history, and an alarm goes off when a parameter leaves its window while the lot is being made.
- The control chart that warns you firstWeighings from the checkweigher become an X̄-R chart with 3σ limits and the Western Electric rules, recalculated at every shift change. A worn nozzle shows up hours before the scrap does, and Cpk shift by shift tells you where to act.
Tell us which machines you run. We'll tell you how to read them.
PLC brand, protocol, how the floor is connected: with those three answers, in a demo with one of our engineers, we show you how Muvia Industrial puts line data next to the rest of the business.