Special requirements in the pharmaceutical and cosmetics industry:

  • lines with different possibilities of rejecting good/bad parts
  • setup with format change
  • process interlock and logic release circuit more
  • key performance indicators (KPIs) service level, productivity, cycle time more
  • electronic logbook for resources in the clean room area

Key performance indicators (KPIs) service level, productivity, cycle time

KPIs service level

The service level report contains the following KPIs:

The number of executed orders regarding a selected resource in the period under consideration is indicated as actual end. If an order is started but not finalised in the period considered, it will not be taken into account. However, if an order starts before and ends in the considered period, it will be counted.

Rate of production orders completed according to schedule:

For example, 10 orders had been planned for January but only 8 were completed, the rate thereof is calculated by dividing the quotient 8 by 10. The quotient of all orders having a scheduled end and those having an actual end in the period considered is calculated accordingly.

Average deviation of production time:

Here, the deviation concerning all orders having a scheduled start and actual start and end in the period under consideration will be calculated by subtracting the scheduled time from the actual time and specifying the difference in working days. As a result a list of orders with positive and negative deviations is created showing the average value at the end of the list.

Average fulfillent level of quantity:

With regard to all orders in the period under consideration, the actual yield is divided by the target quantity. As a result a list of orders and their fulfilment level of the quantity is created and at its end and average value is calculated on the basis of previously calculated percentages.

Service level = average fulfilment level of quantity x rate of the completed production orders according to schedule

KPIs productivity

The productivity report contains the following KPIs:

productivity of working hours = produced OK units/ total man hours of the assigned staff on the resource

machine productivity = produced OK units/ cumulative time of the production status (respectively utilisation time) on the resource in hours.

process quality = idle times in minutes (only downtimes) per 1,000 OK units. For example: Assuming a downtime of 180 minutes on one day with a production of 100,000 OK parts, thus, results in 180/(100,000/1,000)=180/100=1.8.

Cycle time per article

The report ‘cycle time per article’ contains the following KPIs:

Cycle times of each article being produced in multiple production orders is output in a list.

Process interlock and logic release circuit

Firstly, this function is to assure that an order or operation has been released, and secondly, to make supplementary settings in order to specify which states can only be activated on the production terminals.

Each order or operation has a special state of “release” that has to be activated at least once before an operation can be changed or before an order can be changed or logged out. This function, like any other function, can be changed or activated either via office-client or directly on the terminal.

Via a configurable logic release circuit, certain states can only be activated on the production terminal whereas all other states can still be activated via office-client.