Using Equipment Statistics
This guide walks you through configuring and using the Equipment Statistics system to monitor equipment status, calculate OEE, and analyze downtime reasons.
Overview
Equipment Statistics provides three levels of monitoring:
- Status Duration Tracking (Required): Track time spent in each equipment state
- OEE Calculation (Optional): Calculate Overall Equipment Effectiveness metrics
- State Reason Analysis (Optional): Categorize and analyze downtime reasons
💡 Tip: Start with Status Duration Tracking, then add OEE and Reason Analysis as needed.
Configuration Location
Navigate to Basic Management > Equipment Statistics in the development environment.
📷 [Screenshot: Equipment Statistics configuration interface]
Part 1: Status Duration Tracking
Track how long equipment spends in each operational state.
Step 1: Define Equipment States
Define clear, mutually exclusive states for your equipment.
Default States (cannot be deleted, but can be renamed):
- Running: Equipment is producing
- Stopped: Equipment is idle
- Fault: Equipment has an error
Add Custom States:
- Click Add State
- Enter state name (e.g., "Maintenance", "Changeover", "Waiting")
- Assign a unique state value (integer)
- Click Confirm
📷 [Screenshot: Equipment state configuration dialog]
⚠️ Caution: Ensure state values are unique and don't overlap. Equipment should always be in exactly one state.
Example States:
| State Name | State Value | Description |
|---|---|---|
| Running | 1 | Normal production |
| Stopped | 0 | Idle, no production |
| Fault | 2 | Equipment error |
| Maintenance | 3 | Planned maintenance |
| Changeover | 4 | Product changeover |
Step 2: Configure State Detection
Configure how the system determines the current equipment state.
Two Detection Methods:
Method 1: Binary Signals (Multiple Tags)
Each state has its own boolean tag. When a tag is True, that state is active.
- Select Binary Type
- For each state, configure:
- State Signal Tag: Tag that indicates this state (True = active)
Example Configuration:
| State | Signal Tag | Logic |
|---|---|---|
| Running | Line1.Running | True when running |
| Stopped | Line1.Stopped | True when stopped |
| Fault | Line1.Fault | True when fault |
| Maintenance | Line1.Maintenance | True during maintenance |
📷 [Screenshot: Binary signal configuration]
⚠️ Caution: Ensure only one signal is True at a time to avoid state conflicts.
Method 2: Integer Signal (Single Tag)
One integer tag represents all states. Different values indicate different states.
- Select Integer Type
- Configure:
- State Signal Tag: Tag that contains state value
- Each state's value must match the tag value
Example Configuration:
| State | State Value | Tag Value |
|---|---|---|
| Running | 1 | Line1.Status == 1 |
| Stopped | 0 | Line1.Status == 0 |
| Fault | 2 | Line1.Status == 2 |
| Maintenance | 3 | Line1.Status == 3 |
📷 [Screenshot: Integer signal configuration]
💡 Tip: Integer method is simpler and reduces tag count, but requires PLC to provide a single status value.
Step 3: Configure Output Variables (Optional)
Assign tags to receive real-time duration values for each state.
- For each state, configure:
- Output Tag: Tag to receive duration in minutes
Example Configuration:
| State | Output Tag | Description |
|---|---|---|
| Running | Line1.RunningTime | Minutes in Running state |
| Stopped | Line1.StoppedTime | Minutes in Stopped state |
| Fault | Line1.FaultTime | Minutes in Fault state |
📷 [Screenshot: Output variable configuration]
💡 Tip: Output variables update every minute and reset at the start of each shift/day (based on Real-time Range setting).
Step 4: Configure Global Settings
Configure system-wide settings for all equipment.
Real-time Range:
- Current Shift: Reset counters at shift change
- Current Day: Reset counters at midnight
Data Reset Signal (Optional):
- Configure a tag that triggers data reset when it becomes True
- Used to prevent counter overflow in PLC
- System records current values before reset
- Manually reset the signal after triggering
📷 [Screenshot: Global settings configuration]
Step 5: Add Equipment
Add equipment to monitor.
- Click Add Equipment
- Enter equipment name
- Configure state signals for this equipment
- Configure output variables (if using)
- Click Save
📷 [Screenshot: Equipment configuration]
Step 6: Configure Classification Fields (Optional)
Add custom classification fields to categorize equipment.
Use Cases:
- Group by work center, production line, or area
- Filter reports by equipment type or model
- Aggregate data by classification
Configuration:
- Click Classification Fields
- Add fields (e.g., "Work Center", "Line", "Equipment Type")
- For each equipment, set field values
- Use toggle button to show/hide fields in equipment list
📷 [Screenshot: Classification fields configuration]
Example Classifications:
| Equipment | Work Center | Line | Equipment Type |
|---|---|---|---|
| Mixer-01 | Mixing | Line A | Mixer |
| Mixer-02 | Mixing | Line B | Mixer |
| Filler-01 | Filling | Line A | Filler |
Step 7: Save Configuration
Click Save to save all settings and start monitoring.
Part 2: OEE Calculation
Calculate Overall Equipment Effectiveness and its components.
Understanding OEE
OEE measures equipment effectiveness through three factors:
OEE = Availability × Performance × Quality
Availability: Actual running time / Planned running time
Performance: (Theoretical cycle time × Actual output) / Actual running time
Quality: (Actual output - Scrap) / Actual output
Additional Metrics:
- Achievement Rate: Actual output / Planned output
💡 Tip: World-class OEE is typically 85% or higher.
OEE Calculation Example
Scenario: 8-hour shift (480 minutes planned)
Data:
- Planned running time: 480 minutes
- Actual running time: 420 minutes (60 minutes downtime)
- Theoretical cycle time: 1 minute/piece
- Actual output: 380 pieces
- Scrap: 19 pieces
Calculations:
- Availability = 420 / 480 = 87.5%
- Performance = (1 × 380) / 420 = 90.5%
- Quality = (380 - 19) / 380 = 95.0%
- OEE = 87.5% × 90.5% × 95.0% = 75.3%
Step 1: Enable OEE Calculation
- Check Enable OEE Calculation in global settings
- OEE configuration options appear
Step 2: Configure Production Counters
Configure tags that track production output and quality.
For each equipment, configure:
| Parameter | Description | Example Tag |
|---|---|---|
| Output Counter | Cumulative production count (good + scrap) | Line1.TotalOutput |
| Scrap Counter | Cumulative scrap count | Line1.ScrapCount |
📷 [Screenshot: Production counter configuration]
⚠️ Caution: Output counter must include both good parts and scrap. Good parts = Output - Scrap.
Step 3: Configure OEE Parameters
Configure parameters used in OEE calculations.
For each equipment, configure:
| Parameter | Description | Example | Notes |
|---|---|---|---|
| Theoretical Cycle Time | Ideal time to produce one piece (seconds) | 60 | Based on equipment capability |
| Planned Running Time | Planned production time per day (minutes) | 480 | Update daily before production |
| Planned Output | Target production quantity per day | 400 | Update daily before production |
📷 [Screenshot: OEE parameter configuration]
💡 Tip: Planned Running Time and Planned Output can be linked to tags for easy daily updates from HMI.
Example Configuration:
| Equipment | Cycle Time (s) | Planned Time (min) | Planned Output |
|---|---|---|---|
| Mixer-01 | 120 | 480 | 240 |
| Filler-01 | 60 | 480 | 480 |
| Packager-01 | 30 | 480 | 960 |
Step 4: Configure OEE Output Variables (Optional)
Assign tags to receive real-time OEE metrics.
For each equipment, configure output tags:
| Metric | Output Tag | Description |
|---|---|---|
| Availability | Line1.Availability | Time utilization rate (%) |
| Performance | Line1.Performance | Speed utilization rate (%) |
| Quality | Line1.Quality | Quality rate (%) |
| OEE | Line1.OEE | Overall effectiveness (%) |
| Achievement Rate | Line1.Achievement | Output vs. plan (%) |
| Actual Output | Line1.ActualOutput | Current output count |
| Good Parts | Line1.GoodParts | Good parts count |
| Scrap | Line1.Scrap | Scrap count |
📷 [Screenshot: OEE output variable configuration]
Step 5: Save Configuration
Click Save to enable OEE calculation.
Part 3: State Reason Analysis
Categorize equipment states and record specific reasons for downtime.
Understanding State Reason Analysis
Three-Level Structure:
Equipment State → State Category → State Reason
Example:
- State: Stopped
- Category: Planned Downtime
- Reason: Scheduled Maintenance
- Reason: Shift Change
- Category: Unplanned Downtime
- Reason: Material Shortage
- Reason: Equipment Breakdown
- Category: Planned Downtime
Step 1: Enable Reason Analysis
- Check Enable State Reason Analysis in global settings
- Reason analysis configuration options appear
Step 2: Define State Categories
Create categories for each equipment state.
- Select an equipment state (e.g., "Stopped")
- Click Add Category
- Enter category name (e.g., "Planned Downtime", "Material Wait")
- Assign a unique category value (integer)
- Click Confirm
📷 [Screenshot: State category configuration]
Example Categories for "Stopped" State:
| Category | Value | Description |
|---|---|---|
| Planned Downtime | 1 | Scheduled stops |
| Changeover | 2 | Product changeover |
| Material Wait | 3 | Waiting for materials |
| Breakdown | 4 | Equipment failure |
| Unidentified | 0 | Unknown reason (default) |
💡 Tip: "Unidentified" category is automatically created and used when no other category matches.
Step 3: Configure Category Detection
Configure how the system determines the current state category.
For each equipment, configure:
| Parameter | Description | Example |
|---|---|---|
| Category Signal Tag | Tag that contains category value | Line1.StopCategory |
Category Priority:
- If multiple categories could match, the first one in the list is used
- Reorder categories to adjust priority
📷 [Screenshot: Category signal configuration]
Step 4: Configure Reason Recording
Configure how specific reasons are recorded.
For each equipment, configure:
| Parameter | Description | Example |
|---|---|---|
| Reason Signal Tag | Tag that contains reason code or text | Line1.StopReason |
Reason Entry Methods:
- Automatic: PLC writes reason code to tag
- Manual: Operator enters reason through HMI
- Hybrid: PLC provides category, operator provides specific reason
📷 [Screenshot: Reason signal configuration]
💡 Tip: If no reason is provided, the record will have an empty reason field. Use the Reason Management component to fill in missing reasons.
Step 5: Save Configuration
Click Save to enable reason analysis.
Using Equipment Statistics Data
Real-time Monitoring
Display current equipment status and metrics on HMI views.
Status Duration:
- Link output variables to display components
- Show current state and duration
- Update every minute
OEE Metrics:
- Display OEE and its components (Availability, Performance, Quality)
- Show actual vs. planned output
- Visualize with gauges or progress bars
📷 [Screenshot: Real-time OEE dashboard]
Historical Analysis
Query and analyze historical data from automatically generated tables.
Status Duration Records Table
Contains detailed state change records.
| Field | Description |
|---|---|
| Equipment Name | Equipment identifier |
| Equipment State | State name |
| State Category | Category name (if enabled) |
| State Reason | Specific reason (if provided) |
| Start Time | State start timestamp |
| End Time | State end timestamp |
| Duration (min) | Time in state |
| Shift | Shift identifier |
| Shift Date | Date of shift |
| Classification Fields | Custom fields (if configured) |
Usage:
- Create Gantt charts showing state timeline
- Generate pie charts of state duration distribution
- Filter by time range, state, category, or reason
- Drill down from state to category to reason
📷 [Screenshot: State duration Gantt chart]
Status Duration Shift/Day Aggregation Table
Contains aggregated data by shift and day.
| Field | Description |
|---|---|
| Equipment Name | Equipment identifier |
| Equipment State | State name |
| Duration (min) | Total time in state |
| Statistics Time | Aggregation period |
| Statistics Shift | Shift identifier |
| Classification Fields | Custom fields |
Usage:
- Compare state durations across shifts
- Analyze daily/weekly/monthly trends
- Identify patterns and anomalies
📷 [Screenshot: State duration trend chart]
OEE Records Table
Contains detailed OEE snapshots (updated every minute).
| Field | Description |
|---|---|
| Equipment Name | Equipment identifier |
| Statistics Time | Snapshot timestamp |
| Output | Total output count |
| Good Parts | Good parts count |
| Scrap | Scrap count |
| Actual Running Time | Running time (min) |
| Planned Running Time | Planned time (min) |
| Theoretical Output | Ideal output count |
| Availability | Time utilization (%) |
| Performance | Speed utilization (%) |
| Quality | Quality rate (%) |
| OEE | Overall effectiveness (%) |
| Achievement Rate | Output vs. plan (%) |
Usage:
- Plot OEE trends over time
- Identify OEE loss contributors
- Compare equipment performance
📷 [Screenshot: OEE trend chart with components]
OEE Shift/Day Aggregation Tables
Contains aggregated OEE data by shift and day.
Usage:
- Generate shift reports
- Compare shift performance
- Track daily/weekly/monthly OEE
📷 [Screenshot: Shift OEE comparison chart]
Reason Management Components
Two pre-built components help manage state reasons.
Component 1: Manual Reason Entry
Allows operators to enter reasons for unidentified states.
Location: Components > Runtime > Manual Reason Entry
Features:
- Display unidentified state records
- Select state category from predefined list
- Select or enter specific reason
- Update record with reason information
Usage:
- Add component to operator HMI view
- Operators review unidentified states
- Select appropriate category and reason
- Save to update record
📷 [Screenshot: Manual reason entry component]
💡 Tip: Establish procedures requiring operators to enter reasons promptly for accurate data.
Component 2: Reason Library Management
Manage the library of predefined reasons.
Location: Components > Runtime > Reason Library Management
Features:
- Add new reasons to categories
- Rename existing reasons
- Merge similar reasons
- View records associated with each reason
- Import/export reason library
Usage:
- Add component to management view
- Define standard reasons for each category
- Periodically review and consolidate reasons
- Export reason library for backup
📷 [Screenshot: Reason library management component]
Best Practices:
- Create a standardized reason library
- Limit reasons to 10-15 per category
- Use clear, specific reason descriptions
- Train operators on reason selection
- Review and consolidate reasons quarterly
Component 3: State Record Management
View and edit historical state records.
Location: Components > Runtime > State Record Management
Features:
- Query state records by time, equipment, state, category, reason
- Edit reason information for existing records
- Filter unidentified or empty reason records
- Export records for analysis
Usage:
- Add component to management view
- Query records needing correction
- Update reason information
- Export data for reporting
📷 [Screenshot: State record management component]
Best Practices
Configuration
State Definition:
- Define clear, mutually exclusive states
- Use standard state names across similar equipment
- Limit to 5-8 states per equipment
- Document state definitions
Signal Configuration:
- Verify signal connections before going live
- Test state transitions thoroughly
- Use integer signals when possible (simpler)
- Monitor signal quality and reliability
OEE Parameters:
- Set accurate theoretical cycle times
- Update planned time and output daily
- Verify counter accuracy (output = good + scrap)
- Calibrate counters regularly
Reason Categories:
- Create standardized category structure
- Align categories with improvement initiatives
- Limit to 5-10 categories per state
- Document category definitions
Operation
Data Quality:
- Train operators on reason entry procedures
- Review unidentified states daily
- Establish data quality metrics
- Audit data accuracy regularly
Reason Management:
- Maintain a concise reason library
- Consolidate similar reasons
- Update reason library based on feedback
- Document reason definitions
Performance Monitoring:
- Display real-time OEE on production floor
- Set OEE targets and track progress
- Review OEE trends in daily meetings
- Celebrate improvements
Analysis
Root Cause Analysis:
- Use Pareto charts to identify top downtime contributors
- Drill down from categories to specific reasons
- Correlate downtime with other factors (shift, product, etc.)
- Prioritize improvement initiatives based on data
Continuous Improvement:
- Set improvement targets for each OEE component
- Track improvement project impact
- Share best practices across equipment
- Review and adjust targets quarterly
Reporting:
- Generate automated shift reports
- Create executive dashboards
- Export data for advanced analysis
- Archive historical data
Troubleshooting
Equipment State Not Updating
Problem: Equipment stays in one state despite signal changes.
Possible Causes:
- Signal tag not updating
- State value mismatch
- Multiple signals True simultaneously (binary mode)
Solutions:
- Verify tag communication with equipment
- Check state value configuration matches PLC values
- Ensure only one binary signal is True at a time
- Review system logs for errors
OEE Calculation Incorrect
Problem: OEE values don't match manual calculations.
Possible Causes:
- Incorrect theoretical cycle time
- Wrong planned running time
- Counter overflow or reset
- Output counter doesn't include scrap
Solutions:
- Verify cycle time matches equipment capability
- Confirm planned time is set correctly
- Use data reset signal to handle counter overflow
- Ensure output = good parts + scrap
- Check counter accuracy with manual count
Reasons Not Recording
Problem: State records show empty reasons.
Possible Causes:
- Reason signal tag not configured
- PLC not writing reason values
- Operator not entering reasons
Solutions:
- Configure reason signal tag
- Verify PLC writes reason codes
- Train operators on reason entry
- Use Manual Reason Entry component
- Establish procedures for reason entry
Category Detection Not Working
Problem: All states recorded as "Unidentified" category.
Possible Causes:
- Category signal tag not configured
- Category values don't match PLC values
- Signal not updating
Solutions:
- Configure category signal tag
- Verify category values match PLC
- Check tag communication
- Test category transitions manually
Performance Issues
Problem: System slow or data updates delayed.
Possible Causes:
- Too many equipment configured
- High-frequency data updates
- Large historical data volume
Solutions:
- Limit to 50-100 equipment per system
- Use 1-minute update interval (default)
- Archive old data regularly
- Optimize database queries
- Consider separate systems for different areas
Next Steps
Now that you know how to use Equipment Statistics, explore:
- Understanding Data Management: Analyze equipment statistics data
- Creating Analytics Dashboards: Build OEE dashboards
- Using Recipe Management: Manage production recipes
Related Topics
- Understanding Applications: Learn about the Applications module
- Understanding Tags: Configure equipment signal tags
- Creating Event-Actions: Automate equipment monitoring workflows