Manufacturing

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.

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.

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, with fields for Part, Revision, Line Configuration, Centerlining Group, Work Order Type, and Sensor Count Multiplier.

Routing

Defines the manufacturing steps required to produce a formula. Each routing has a Formula, Operation, Time Type (Per Unit or Fixed), Run Time (min), Quantity, and Expected Yield (%).

Facility

Represents manufacturing locations or plants, with Name, Loaded Cost per Worker, and Time Zone.

Line

Represents production lines or work centers, with Name, Facility, Standard Availability / Performance / Quality percentages, Operators, and Loaded Cost per Worker. Line availability windows are no longer stored as day-of-week fields on the Line itself; use Operating Schedule and Holiday Schedule instead.

Line Component

Represents equipment or sections within a production line that can experience incidents, with Line and Name.

Incident Type

Categorizes incidents and determines whether they count as downtime, via a Machine Downtime flag (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, with Line Component and Name.

Shift

Defines work shifts for grouping production and assigning shift/date, with Name, Start Time, End Time, and Date Offset (Same Day, Prior Day, or Next Day for overnight shifts).

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.

Production Scheduling Tables

These tables define when facilities and lines are available to run. Schedules cascade from more general to more specific: global to facility to line.

Operating Schedule

Recurring weekly availability windows, with optional Facility and Line scoping, Days of Week, and Start Time / End Time.

Holiday Schedule

Date/time overrides for holidays, shutdowns, or special available periods, with Name, Type (Unavailable or Available), Facility / Line scope, and Start/End Date & Time. Facility Time Zone is used when interpreting these schedules.

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), with Number, Type (Production Job, Preventative Maintenance, Corrective Maintenance, Improvement Project, or Changeover), Status (None, Planning, Active, Paused, Completed, Closed, or Canceled), Formula, Facility, Line / Line Component, Line Configuration, Planned Quantity, Line Operators, and calculated Finished Quantity and OEE / Availability / Performance / Quality.

Work Order Routing

Links work orders to specific routing steps and tracks execution timing and labor, with Work Order, Routing, Line, Shift, Shift Date, Planned Start / Finish, Actual Start / Finish, Line Operators, and calculated Labor Cost.

Line Finish

Records production output at specific points in time, with Work Order Routing, Quantity, and Timestamp.

Quality Rejection

Records defective or rejected parts, with Work Order Routing, Quantity, and Timestamp.

Incident

Records downtime events and production interruptions, with Work Order Routing, Start / Finish, Incident Type, Line Component, and Incident Reason.

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 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, with Name, Line, Sort, Type (Count or Weight), Line Component, For Incident Tracking, Incident Threshold (ms), For Line Finishes, Finish Threshold (ms), Record Throughput, Incident Type, Count Multiplier, and Tare Weight.

Line Configuration

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

Sensor Configuration

Formula- or configuration-specific sensor settings that override sensor defaults, used when lines are reconfigured based on the product being produced.

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 assigned to formulas), Production Checklist (captured against a work order), Centerlining Result / Centerlining Result Detail (recorded values), and Quality Audit Checklist (scoped by Facility to Line to Line Component).

Maintenance Tables

Maintenance Part: parts used in maintenance workflows, scoped by Facility to Line to Line Component.

Table Relationships

Understanding how tables connect helps you navigate and analyze your production data: Work Orders contain multiple Routings; Line Finishes, Quality Rejections, Incidents, and Throughput are recorded against specific routings (or sensors); Lines contain Components, and Sensors monitor activity on the line/component; Formulas define the sequence of Routings; Formulas and Work Orders link to Line Configuration and Sensor Configuration for product- or job-specific sensor behavior; Operating and Holiday Schedules apply to Facility / Line for availability and OEE; Components have specific Incident Reasons; and Formulas link to a Centerlining Group whose targets flow into Production Checklists.

Work Order Lifecycle

Use Type and Status to manage jobs end to end:

1. Create a work order (often Type = Production Job, Status = Planning).
2. Assign formula, facility/line, planned quantity, and work order routings (planned start/finish).
3. Start the job (Status = Active, Actual Start set on the routing).
4. Capture finishes, rejections, incidents, and optional production checklists while Status = Active (or Paused).
5. 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. See Reports for the full list of report types, dimensions, metrics, filters, and use cases.

OEE Calculations

Overall Equipment Effectiveness (OEE) measures manufacturing productivity using three factors: Availability (uptime), Performance (speed), and Quality (good parts).

OEE = Availability x Performance x Quality. Example: 85% Availability x 90% Performance x 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 x 100

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.

Example

A Work Order Routing runs from 8:00 AM to 4:00 PM (8 hours, or 480 minutes). An equipment breakdown of 30 minutes (Machine Downtime checked) and a planned changeover of 15 minutes (Machine Downtime unchecked) occur. Downtime = 30 minutes (only the breakdown counts). Availability = (480 - 30) / 480 = 93.8%. 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, and 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 x 100.

Example: a routing has a standard of 100 units per hour. Production runs 6 hours and produces 540 units. Expected Output = 100 x 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 x 100.

Example: production completes 1,000 units but rejects 50 defective units. Good Units = 1,000 - 50 = 950. Quality = 950 / 1,000 = 95.0%.