Manufacturing App

The Production Module is Essembi’s manufacturing module for an app. It adds pre-configured tables, fields, reports, and floor workflows for work orders, routings, lines, incidents, sensors, OEE, run rates, labor costing, scheduling, and quality.

Related help: Available Reports · Sensors · Edge Devices

Licensed Feature Packs

Depending on your license, the module can include:

Productivity — Finishes, incidents, sensors, throughput, and related production analytics
Quality — Centerlining groups/steps, production checklists, and quality audit checklists
Maintenance — Maintenance part master data
Production Scheduling — Operating schedules, holiday schedules, and timeline scheduling roles on work orders / routings

Table and Field Structure

The production module includes a comprehensive set of pre-configured tables and fields for managing manufacturing operations, tracking production data, and analyzing performance. These tables work together to provide complete visibility into your production processes.

Master Data Tables

These tables define the fundamental structure of your manufacturing operations.

Formula

Each formula represents a unique part and revision combination that can be manufactured.

Part — The part number or product identifier
Revision — Version or revision level of the formula
Line Configuration — Optional reference to sensor configuration settings for this product
Centerlining Group — Optional quality centerlining group used when production checklists are created
Work Order Type — Optional filter so only matching formulas appear for a given work order type
Sensor Count Multiplier — Optional formula-level multiplier applied to sensor finish counts

Routing

Defines the manufacturing steps required to produce a formula. Each routing represents one operation in the production process.

Formula — The product this routing belongs to
Operation — Name of the manufacturing step
Time Type — Per Unit or Fixed
Run Time (min) — Standard time to complete this operation
Quantity — Quantity associated with the run time
Expected Yield (%) — Expected percentage of good parts from this operation

Facility

Represents manufacturing locations or plants.

Name — Facility identifier
Loaded Cost per Worker — Default hourly labor cost including benefits and overhead
Time Zone — Time zone used when interpreting operating and holiday schedules for the facility

Line

Represents production lines or work centers where manufacturing occurs.

Name — Production line identifier
Facility — The facility where this line is located
Standard Availability % — Target availability percentage for this line
Standard Performance % — Target performance percentage for this line
Standard Quality % — Target quality percentage for this line
Operators — Default number of operators for this line
Loaded Cost per Worker — Hourly labor cost for this line (overrides facility cost)

Line availability windows are no longer stored as day-of-week fields on the Line itself. Use Operating Schedule and Holiday Schedule (see Production Scheduling below).

Line Component

Represents equipment or sections within a production line that can experience incidents.

Line — The production line this component belongs to
Name — Component identifier (e.g., "Mixer", "Oven", "Packaging Station")

Incident Type

Categorizes incidents and determines whether they count as downtime.

Machine Downtime — Whether this incident type reduces availability (checked = unplanned downtime that lowers Availability; unchecked = planned time that is tracked but does not lower Availability)

Incident Reason

Provides specific reasons for incidents on particular line components.

Line Component — The equipment this reason applies to
Name — Description of the incident reason

Shift

Defines work shifts for grouping production and for assigning shift/date when jobs are started.

Name — Shift identifier (e.g., "First Shift", "Second Shift", "Night Shift")
Start Time — Shift start time
End Time — Shift end time
Date Offset — Same Day, Prior Day, or Next Day (used for overnight shifts when calculating Shift Date)

Run Rate Rule

Optional overrides for routing standards based on work order dataset fields. When a rule matches, its Run Time, Quantity, and/or Expected Yield can replace the routing defaults used by OEE, run rate, labor, and active job calculations.

Name — Rule identifier
Run Time (min) — Optional override run time
Quantity — Optional override quantity
Expected Yield (%) — Optional override yield
Rule Field (additional settings) — Links the rule to a field on Work Order, Work Order Routing, Formula, or Routing so the rule can be resolved for the current job

Production Scheduling Tables

These tables (Production Scheduling feature) define when facilities and lines are available to run. Schedules cascade from more general to more specific: global → facility → line.

Operating Schedule

Recurring weekly availability windows.

Facility — Optional; leave blank for a global schedule, or set to apply at a facility
Line — Optional; set to apply to a specific line within the facility
Days of Week — Which days the window applies
Start Time / End Time — Daily operating window

Holiday Schedule

Date/time overrides for holidays, shutdowns, or special available periods.

Name — Override identifier
Type — Unavailable or Available
Facility / Line — Scope of the override (same cascade as operating schedules)
Start Date & Time / End Date & Time — Override window

Facility Time Zone is used when interpreting these schedules. Timeline views can also use operating schedules via the view’s Use Operating Schedule option.

Work Order Tables

These tables manage work orders (jobs) and track their execution through manufacturing routings.

Work Order

Represents a production order (or other job type) to manufacture a product or complete related work.

Number — Unique work order identifier
Type — Production Job, Preventative Maintenance, Corrective Maintenance, Improvement Project, or Changeover
Status — None, Planning, Active, Paused, Completed, Closed, or Canceled
Formula — The product to be manufactured (filtered by Work Order Type when formulas specify a type)
Facility — Where production will occur
Line / Line Component — Optional line and component assignment
Line Configuration — Optional sensor configuration for this job (often defaulted from the formula)
Planned Quantity — Target quantity to produce
Line Operators — Number of operators assigned to this work order
Finished Quantity (calculated) — Total quantity produced
OEE / Availability / Performance / Quality (calculated) — Effectiveness metrics for this work order

Note: Older help referred to an “Active Job” checkbox. That has been replaced by Status = Active.

Work Order Routing

Links work orders to specific routing steps and tracks execution timing and labor.

Work Order — The production order
Routing — The manufacturing operation to perform
Line — Production line where this routing will execute
Shift — Shift assignment for this routing
Shift Date — Calendar date of the shift (supports overnight shifts via Shift Date Offset)
Planned Start / Planned Finish — Scheduled window
Actual Start / Actual Finish — When production actually began and completed
Line Operators — Number of operators assigned to this routing
Labor Cost (calculated) — Total labor expense for this routing

Line Finish

Records production output at specific points in time.

Work Order Routing — The routing step this finish is associated with
Quantity — Number of units completed
Timestamp — When the quantity was finished

Quality Rejection

Records defective or rejected parts.

Work Order Routing — The routing step where rejection occurred
Quantity — Number of units rejected
Timestamp — When the rejection was recorded

Incident

Records downtime events and production interruptions.

Work Order Routing — The routing affected by this incident
Start / Finish — When the incident began and was resolved
Incident Type — Category of incident
Line Component — Equipment that experienced the incident
Incident Reason — Specific reason for the incident

Throughput

Records mid-line sensor counts (when a Count sensor has Record Throughput enabled), linked to the sensor and optionally to a work order routing.

Sensor — Sensor that recorded the count
Work Order Routing — Optional routing association
Quantity — Counted quantity
Timestamp — When the count was recorded

Sensor Configuration Tables

These tables manage the configuration of sensors for collecting real-time data from the production floor. See also Edge Devices for local Pulse collection.

Sensor

Configures sensors that automatically record production counts, weight, throughput, and/or incidents.

Name — Sensor identifier
Line — Production line this sensor belongs to
Sort — Display / processing order
Type — Count or Weight
Line Component — The line component physically before the sensor on the production line. For example, if you install a sensor between the filler and the checkweigher, assign the sensor to the filler.
For Incident Tracking — When checked, this sensor can automatically log incidents
Incident Threshold (ms) — Idle time required before an incident is automatically logged (defaults to 5 minutes)
For Line Finishes — When checked, this sensor is the completed-unit count sensor for the line (typically at the end of the line)
Finish Threshold (ms) — Required time between captured finish records
Record Throughput — When checked on a Count sensor, mid-line counts are written to the Throughput table
Incident Type — Type assigned to incidents logged from the sensor (defaults to Downtime)
Count Multiplier — Multiplier from sensor signals to finished quantity (e.g., 6 units per cycle)
Tare Weight — Used when Type = Weight

Line Configuration

Groups sensor configurations that can be applied to different formulas or work orders.

Name — Configuration identifier

Sensor Configuration

Formula- or configuration-specific sensor settings that override sensor defaults. Use this when lines are reconfigured based on the product being produced (for example, disabling incident tracking for a product that runs without a station).

Sensor — Sensor being overridden
Line Configuration — Configuration group this override belongs to
For Line Finishes / For Incident Tracking — Optional overrides
Incident Threshold (ms) / Finish Threshold (ms) / Count Multiplier — Optional overrides

Production Automation (App Settings)

Under Settings → App Settings → Production Automation, you can control how sensor finishes are bucketed/rounded (for example, round finishes to 1, 5, 15, 30, or 60 minute boundaries).

Quality Tables

These tables support centerlining and production quality checklists (Quality feature).

Centerlining Group / Centerlining Step — Master targets (Step, Target, Minimum, Maximum) assigned to formulas
Production Checklist — Checklist captured against a work order; steps can auto-populate from the formula’s centerlining group
Centerlining Result / Centerlining Result Detail — Recorded values for each step on a checklist
Quality Audit Checklist — Audit checklist master data scoped by Facility → Line → Line Component

Maintenance Tables

Maintenance Part — Parts used in maintenance workflows, scoped by Facility → Line → Line Component

Table Relationships

Understanding how tables connect helps you navigate and analyze your production data:

Work Orders → Routings — Each work order contains multiple routing steps
Routings → Production Data — Line finishes, quality rejections, incidents, and throughput are recorded against specific routings (or sensors)
Lines → Components → Sensors — Each line contains components; sensors monitor activity on the line/component
Formulas → Routings — Each formula defines the sequence of operations required
Formulas / Work Orders → Line Configuration → Sensor Configuration — Product- or job-specific sensor behavior
Operating / Holiday Schedules → Facility / Line — Availability windows used by scheduling and OEE
Components → Incident Reasons — Each component has specific reasons for incidents
Formulas → Centerlining Group → Production Checklist — Quality targets flow into job checklists

Work Order Lifecycle

Use Type and Status to manage jobs end to end:

Create a work order (often Type = Production Job, Status = Planning).
Assign formula, facility/line, planned quantity, and work order routings (planned start/finish).
Start the job (Status = Active, Actual Start set on the routing). Forms and timelines can use the workOrder scripting helpers to start a job on a line and stop other active jobs on that line.
Capture finishes, rejections, incidents, and optional production checklists while Status = Active (or Paused).
Complete and close the job (Status = Completed / Closed), or cancel if it will not run.

Active work orders and sensor/floor APIs typically key off work orders with Status = Active and production routings that have an Actual Start.

Available Reports

The production module includes reports for OEE, run rates, labor costs, active work orders, throughput, production events, and more. These are available as report data sources when setting up any view in Essembi.

For the full list of report types, dimensions, metrics, filters, and use cases, see the available reports help page.

From OEE bucket views, users can also drill into Finishes, Incidents, Rejections, and Routings, and use Explain with AI for a narrative summary of the selected bucket.

OEE Calculations

Overall Equipment Effectiveness (OEE) measures manufacturing productivity using three factors: Availability (uptime), Performance (speed), and Quality (good parts). For more details, see the Essembi blog post “What is OEE?”.

OEE = Availability × Performance × Quality

Example: 85% Availability × 90% Performance × 95% Quality = 72.6% OEE

Run rate standards used in Performance can come from the Routing, or from a matching Run Rate Rule when one applies.

Step 1: Availability (Uptime)

Availability measures what percentage of your scheduled production time was actually used for production.

Availability = (Run Time - Downtime) ÷ Run Time × 100

Where the Data Comes From

Data Element	Source in Essembi
Run Time	Work Order Routing: Actual Finish minus Actual Start (For in-progress jobs, current time is used instead of Actual Finish). When operating schedules apply, only time inside available schedule windows counts as Run Time.
Downtime	Incident: Sum of time between Start and Finish Only includes incidents where Incident Type → Machine Downtime is checked

How Operating Schedules Affect Availability

Availability can respect Operating Schedule and Holiday Schedule windows resolved for the line (and facility), using the facility time zone:

When schedule availability is applied, nights/weekends/holidays marked unavailable are excluded from Run Time so they do not artificially lower Availability.
Holiday Schedule Type = Unavailable removes time; Type = Available can add special available windows.
Timeline views also expose a Use Operating Schedule option for scheduling against these windows.

Example

A Work Order Routing runs from 8:00 AM to 4:00 PM (8 hours). Two incidents occur:

Equipment breakdown: 30 minutes (Incident Type with Machine Downtime checked)
Planned changeover: 15 minutes (Incident Type with Machine Downtime unchecked)

Run Time = 480 minutes
Downtime = 30 minutes (only the breakdown counts)
Availability = (480 - 30) ÷ 480 = 93.8%

Note: The planned changeover does not reduce Availability because its Incident Type does not have Machine Downtime checked.

Planned Maintenance

For scheduled maintenance or changeovers:

Create an Incident Type (for example, "Planned Maintenance") with Machine Downtime unchecked
Record the maintenance as an Incident using this type
The time is tracked but does not reduce Availability

Step 2: Performance (Speed)

Performance measures how fast you produced compared to your standard speed.

Performance = Actual Output ÷ Expected Output × 100

Where the Data Comes From

Data Element	Source in Essembi
Actual Output	Line Finish: Sum of Quantity for this Work Order Routing
Expected Output	From Routing Run Time (min) and Quantity (or a matching Run Rate Rule override) Formula: (Run Time ÷ Routing Run Time) × Routing Quantity

Example

A routing has a standard of 100 units per hour. Production runs 6 hours and produces 540 units:

Expected Output = 100 × 6 = 600 units
Actual Output = 540 units
Performance = 540 ÷ 600 = 90.0%

Step 3: Quality (Good Parts)

Quality measures what percentage of your production was good parts (not defective).

Quality = (Total Produced - Rejected) ÷ Total Produced × 100

Where the Data Comes From

Data Element	Source in Essembi
Total Produced	Line Finish: Sum of Quantity
Rejected	Quality Rejection: Sum of Quantity

Example

Production completes 1,000 units but rejects 50 defective units:

Good Units = 1,000 - 50 = 950
Quality = 950 ÷ 1,000 = 95.0%

Related Help

Apps — How apps and modules fit together
Available Reports — Full report catalog
Sensors — Sensor setup and overrides
Edge Devices — Pulse / local collection
Workspaces and Views — Building views on module tables and reports

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