User Stroy: Asset Performance Calculation (AX02US06)

The most globally recognized and effective framework for measuring manufacturing or asset performance is Overall Equipment Effectiveness (OEE). We can adapt its principles to create your Asset Performance Score. OEE is based on three core factors:

1. Availability (related to Uptime): Is the asset running when it's supposed to be?
2. Performance (related to Performance Metrics): Is it operating at its full potential speed?
3. Quality (related to Output Quality): Is it producing good, non-defective output?

Let's build your formula using this proven structure.

Step 1: Define and Calculate the Core Components

We will calculate a score for each of the three OEE components (Availability, Performance, and Quality) on a scale of 0 to 1.

1. Availability Score (A)

This component directly uses your Uptime data. Availability measures the percentage of scheduled time that the asset is actually operational.

• Inputs Needed:
  • Uptime: The total time the asset was running and operational.
  • Planned Operating Time: The total time the asset was scheduled to run. (This is crucial. An asset that is off for a planned holiday is not "unavailable.")
  • Planned Operating time can be deduced from the operational time input taken from while creation system, network and facility and the same applies and if the system and facility time contradicts then system time should be considered and if system time is not available then facility time should be considered and if both are not available then default it to 24/7
• Formula:
  Availability (A) = Uptime / Planned Operating Time
• Example:
  • An asset is scheduled to run for a 24-hour period (Planned Operating Time = 24 hours).
  • It experiences 3 hours of unplanned downtime for repairs.
  • Uptime = 24 - 3 = 21 hours.
  • A = 21 / 24 = 0.875 (or 87.5%)

2. Performance Score (P)

This component uses your Performance Metrics. It measures how close the asset is to its maximum potential speed or output rate while it is running.

• Inputs Needed:
  • Actual Output: The total number of units, volume, or cycles the asset produced.
  • Ideal Run Rate: The theoretical maximum speed or output rate of the asset (e.g., 100 units per hour).
  • Uptime: The time the asset was actually running (from the previous step).
• Formula:
  Performance (P) = Actual Output / (Ideal Run Rate * Uptime)
• Example:
  • An asset's Ideal Run Rate is 100 widgets per hour.
  • It ran for Uptime = 21 hours.
  • Its theoretical maximum output in that time is 100 * 21 = 2100 widgets.
  • However, it only produced an Actual Output of 1800 widgets due to slow cycles or minor stops.
  • P = 1800 / 2100 = 0.857 (or 85.7%)
  • Performance Metrics are gathered form the service orders through readings and it varies from one asset type to other

3. Quality Score (Q)

This component measures the "good" output. It's the percentage of the total output that is free of defects and meets quality standards.

• Inputs Needed:
  • Good Output: The number of units that passed quality inspection.
  • Actual Output: The total number of units produced (from the previous step).
• Formula:
  Quality (Q) = Good Output / Actual Output
• Example:
  • The asset produced a total of Actual Output = 1800 widgets.
  • Upon inspection, 90 of them were found to be defective.
  • Good Output = 1800 - 90 = 1710 widgets.
  • Q = 1710 / 1800 = 0.95 (or 95%)
  • These quality metrics are gathered form the water quality service orders and pick the nearest quality metrics of the nearest parent like systems and facilities and needs to be recalculated overtime the service order is approved.

Step 2: Calculate the Final Asset Performance Score (out of 100)

The final score is calculated by multiplying the three individual component scores together and then scaling the result to 100. This method correctly penalizes the overall score for losses in any of the three areas.

Asset Performance Score = A * P * Q * 100

• Final Example Calculation:
  • Availability (A) = 0.875
  • Performance (P) = 0.857
  • Quality (Q) = 0.95
  • Asset Performance Score = 0.875 * 0.857 * 0.95 * 100 = 71.2

The final Asset Performance Score for this asset is 71.2 out of 100.

The Complete Formula

Asset Performance Score = (Uptime / Planned Operating Time) * (Actual Output / (Ideal Run Rate * Uptime)) * (Good Output / Actual Output) * 100

This can be simplified. Notice that Actual Output and Uptime appear in both the numerator and denominator across terms, allowing for a cleaner final formula:

Asset Performance Score = (Good Output / (Ideal Run Rate * Planned Operating Time)) * 100

While this simplified version is mathematically elegant, the first, component-based version is far more useful for your software. It allows you to show your users why their performance score is what it is. They can see if the primary loss is due to downtime (Availability), slow cycles (Performance), or defects (Quality), which is critical for diagnostics and improvement.

By implementing this OEE-based framework, you are providing a world-class, industry-standard metric that is instantly understandable and actionable for your users.