HORNER OEE Solution User manual

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PREFACE
This manual explains how to use the Horner OEE Solution.
Copyright© 2022 Horner APG, LLC, 59 South State Avenue, Indianapolis, Indiana 46201. All rights
reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the prior agreement and written
permission of Horner APG, Inc.
All software described in this document or media is also copyrighted material subject to the terms and
conditions of the Horner Software License Agreement.
Information in this document is subject to change without notice and does not represent a commitment
on the part of Horner APG.
Ethernet™ is a trademark of Xerox Corporation.
microSD™ is a registered trademark of SanDisk Corporation.
LIMITED WARRANTY AND LIMITATION OF LIABILITY
For more information about the warranty and limitation of liability, please contact the Horner Solutions
Group Manager at 877-665-5666 or visit our website at www.hornersolution.com

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Table of Contents
PREFACE............................................................................................................................................2
LIMITED WARRANTY AND LIMITATION OF LIABILITY ...........................................................................2
Table of Contents ......................................................................................................................................3
1 SAFETY AND COMPLIANCE.............................................................................................................5
1.1 Safety Warnings and Guidelines.................................................................................................5
2 INTRODUCTION..............................................................................................................................7
2.1 OEE Overview..............................................................................................................................7
2.2 Production Data Availability .......................................................................................................8
2.3 Types of Reports .........................................................................................................................8
2.4 Contractual Requirements..........................................................................................................8
3 ELECTRICAL INSTALLATION ............................................................................................................9
3.1 OEE Power Wiring.......................................................................................................................9
3.2 OEE Electrical I/O......................................................................................................................10
4 ELECTRICAL - GROUNDING...........................................................................................................11
4.1 Grounding Definition ................................................................................................................11
4.2 Ground Specifications...............................................................................................................11
4.3 How to Test for Good Ground ..................................................................................................11
5 OEE SYSTEM NAVIGATION...........................................................................................................12
5.1 Home.........................................................................................................................................12
5.2 Trends .......................................................................................................................................14
5.3 Summary...................................................................................................................................17
5.4 Events........................................................................................................................................17
5.5 Downtime Accumulators ..........................................................................................................18
5.6 Call Accumulators .....................................................................................................................18
6 CALLS............................................................................................................................................19
6.1 Placing a Call .............................................................................................................................19
6.2 Acknowledging a Call................................................................................................................20
6.3 Clearing a Call............................................................................................................................20
7 CONFIGURATION..........................................................................................................................22
7.1 Configuration Overview............................................................................................................22
7.2 Cell Configuration .....................................................................................................................23
7.3 Shift Configuration....................................................................................................................26
7.4 Part Editor/Viewer....................................................................................................................28
7.5 Downtime Code Configuration .................................................................................................32
7.6 Ethernet Configuration.............................................................................................................33
7.7 Email Configuration ..................................................................................................................36
7.8 System Information ..................................................................................................................38
8 OEE SCORE CALCULATION OVERVIEW.........................................................................................39
8.1 Availability.................................................................................................................................39
8.2 Performance .............................................................................................................................39
8.3 Quality.......................................................................................................................................39
8.4 Overall Equipment Effectiveness..............................................................................................39
8.5 Scheduled Breaks and Changeover; Effect on Scoring .............................................................39
9 LOGIN / LOGOUT..........................................................................................................................41
9.1 Log In.........................................................................................................................................41

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8.2 Log Out......................................................................................................................................43
10 WORK INTERFACES ......................................................................................................................44
10.1 Work: Detailed ......................................................................................................................44
10.2 Work: Simplified....................................................................................................................47
10.3 Work: Basic............................................................................................................................49
11 DOWNTIME..................................................................................................................................50
11.1 Manual Downtime.................................................................................................................50
11.2 Automatic Downtime............................................................................................................50
11.3 Downtime Code Prompt........................................................................................................50
11.4 Automatic Downtime Code Entry .........................................................................................51
12 PART CHANGEOVER.....................................................................................................................52
12.1 Changeover Mode.................................................................................................................53
13 DATA LOGGING AND STORAGE....................................................................................................54
13.1 Data Logging..........................................................................................................................54
13.2 Data Log Transfer ..................................................................................................................56
13.3 Configuration Storage ...........................................................................................................56
14 CONFIGURATION UTILITY.............................................................................................................58
14.1 Part Configuration.................................................................................................................59
14.2 Shift Configuration ................................................................................................................62
14.3 Downtime Code Configuration .............................................................................................65
14.4 Login Configuration...............................................................................................................66
14.5 Email / SMS Configuration ....................................................................................................68
14.6 File Locations.........................................................................................................................68
15 DATA CONCENTRATOR ................................................................................................................69
15.1 Configuration.........................................................................................................................70
15.2 Web Browser Access.............................................................................................................71
16 MODBUS TCP ACCESS ..................................................................................................................73
16.1 Configuration Information ....................................................................................................73
16.2 OEE Data................................................................................................................................74
16.3 Light Tower and Call Status...................................................................................................75
17 CONTACT INFORMATION.............................................................................................................75
INDEX..............................................................................................................................................76

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1SAFETY AND COMPLIANCE
1.1 Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation.
Warning: Electrical Shock Hazard.
WARNING –EXPLOSION HAZARD –Do not disconnect equipment unless power has been switched off or
the area is known to be non-hazardous
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground
before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to
fuse the voltage measurement inputs. Be sure to locate fuses as close to the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk of fire and
shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated failure indicates
a defective condition that will not clear by replacing the fuse.
WARNING—EXPLOSION HAZARD—Substitution of components may impair suitability for Class I,
Division 2
WARNING: The USB parts are for operational maintenance only. Do not leave permanently connected
unless area is known to be non-hazardous
WARNING—EXPLOSION HAZARD—BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE
NON-HAZARDOUS.
WARNING: Battery May Explode If Mistreated. Do Not Recharge, Disassemble or Dispose Of In Fire.
WARNING: Only qualified electrical personnel familiar with the construction and operation of this
equipment and the hazards involved should install, adjust, operate, or service this equipment. Read
and understand this manual and other applicable manuals in their entirety before proceeding. Failure
to observe this precaution could result in severe bodily injury or loss of life.

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All applicable codes and standards need to be followed in the installation of this product.
For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18 AWG or larger.
Adhere to the following safety precautions whenever any type of connection is made to the module.
a) Connect the green safety (earth) ground first before making any other connections.
b) When connecting to electric circuits or pulse-initiating equipment, open their related breakers.
Do not make connections to live power lines.
c) Make connections to the module first; then connect to the circuit to be monitored.
d) Route power wires in a safe manner in accordance with good practice and local codes.
e) Wear proper personal protective equipment including safety glasses and insulated gloves when
making connections to power circuits.
f) Ensure hands, shoes, and floors are dry before making any connection to a power line.
g) Make sure the unit is turned OFF before making connection to terminals. Make sure all circuits
are de-energized before making connections.
h) Before each use, inspect all cables for breaks or cracks in the insulation. Replace immediately if
defective.

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2INTRODUCTION
2.1 OEE Overview
The Horner OEE Solution is a pre-programmed system that is easy and quick to implement with no
further programming development required by the user end. After a simple initialization setup via the
touchscreen interface (CONFIG /SETUP area), the OEE kit will start collecting and monitoring production
data immediately, though more complex configuration is available as well. This Setup should take
around 30 minutes or less.
The OEE kit provides tools for management, including real-time plant and individual work cell level
visibility of all the work cells that have the Horner OEE machine monitoring solution kit installed and
running on the production floor. The system logs uptime, downtime, good parts, bad parts, and it also
gives the operator the ability to flag the work cell as down and designate why the work cell is down. The
system calculates OEE scores in real time as the part run or shift progresses.
Operators also have a Call for Help function (part of lean manufacturing) to call for raw materials,
maintenance, and supervisors. This gives operators further empowerment with ability to define what
might be causing work processes to miss production quotas.
There is no need to write program logic to use the OEE kit. The system comes pre-programmed and
ready to use as soon as configuration parameters are in place specific to the manufacturing facility in
which the system is installed. The program logic that is in place is not normally accessible.
Management can access OEE data and Call for Help data for understanding production timeline,
analysis, and methods to improve the production process.
Designed to be flexible for diverse types of processes, system configuration allows for:
•Manual cycle and scrap triggers via the touchscreen
•Automatic cycle and scrap triggers via input signals from the manufacturing equipment
•Batch mode operation for single part runs where calculations start over for each part change
•Shift mode operation for calculations that encompass multiple part changes in a single shift
•Part configuration that allows for Changeover times to either affect or not affect OEE scoring
•Shift configuration that allows for multiple break times to either affect or not affect OEE scoring
•Remote access to configuration over an Ethernet network
•Email notification of Calls and for shift-end data log files
•A separate configuration utility that makes constant or cumbersome changes to the system
easier to implement

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2.2 Production Data Availability
Production data is available from the touchscreen interface itself, on displays created separate from
those normally used by the production personnel operating the machine. Management can view shift,
day, week and even monthly production data and information.
A separate Data Concentrator allows monitoring of up to 32 OEE stations brought to a single point. The
centralized data can be accessed with any Internet Browser for both large-screen production monitor
viewing and mobile device viewing.
OEE offers three main points of data to gather data to lead to more productive and valuable operating
time:
•Availability Loss –Due to unplanned stops, equipment failure, planned stops, and setup
adjustments.
•Performance Loss –Due to small stops, idling or minor stops, slow cycles, and reduced speed.
•Quality Loss –Due to production rejects, process defects, startup rejects, and reduced yield.
2.3 Types of Reports
Reports offered by OEE:
•Production Log Data is available to all users on the network
•Downtime durations and reason codes
•Call for help, Acknowledge Call and Clear Call for help data log files.
•Log files created in CSV format for the ability to create custom dashboards and reports
2.4 Contractual Requirements
There are contractual requirements and a signed NDA required for anyone that wants access to the
Intellectual Property of the Horner Solutions Group contained in the OEE solution kit for any
customization of the logic already in place.
The OEE Machine Monitoring Solution Program allows configuration changes and adjustments to
parameters that need to be tailored for each customer’s individual work cell requirements. Also, this
program in locked down and password protected from viewing, copying, changing, uploading or
downloading logic, data log setup, or operator interface displays. If a customer, channel partner, or
system integrator would like to modify the program logic, operator interface screens, or data log
information, they must contact the factory to discuss with Horner Solutions Group Manager.
Each of these cases will be handled on a case-by-case basis determined by volume of the opportunity,
who requested the modification. Finally, a signed NDA protecting the IP of this product for the Horner
Solutions Group is needed, including who will support the application changes that are made and what
the costs are that are associated with the individual project requirements.
To contact the factory, please contact the Horner Solutions Group Manager at 877-665-5666.

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3ELECTRICAL INSTALLATION
3.1 OEE Power Wiring

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3.2 OEE Electrical I/O