Data Visualization and Interpretation Overview 226

5 Why

A troubleshooting process that involves asking a series of “why” questions, usually five, in order to isolate the root cause of a problem. The 5 Why method can be incorporated into other troubleshooting techniques.

5M plus 1P

5M + 1P. A method commonly known as 6M that is used during brainstorming to help identify the six major factors most likely to be the source of problems. The 5M + 1P categories are machinery, materials, methods, measurements, Mother Nature (process), and people (manpower).

6M

A method sometimes known as 5M + 1P that is used during brainstorming to help identify the six major factors most likely to be the source of problems. The 6M categories are machinery, materials, manpower (people), methods, measurements, and Mother Nature (process).

abnormalities

An unusual or unexpected feature or occurrence. Abnormalities are a sign of a problem in a process.

andon

A visual management tool that highlights the status of operations in an area and signals whenever an abnormality occurs. Andon is the Japanese word for “lantern.”

artificial intelligence

AI. A computer program with algorithms that enable a machine or computer to imitate intelligent human behavior. Artificial intelligence allows machines to perform a process with autonomy.

average

A number expressing the central or expected value within a set of values. The average of a set of values is equal to the sum of the values divided by the number of values in the set.

bearings

A device that allows one moving part to glide past another moving part without excess wear or friction. Bearings work using a sliding or rolling mechanism.

benchmarks

The practice of comparing one set of data to another set of data. Benchmarking can allow companies to compare themselves to competitors or compare current and previous data to determine results.

bottlenecks

A point of congestion during the production process. Bottlenecks limit the flow of products.

brainstorming

An activity in which an individual or group rapidly lists ideas in order to identify possible problem causes or solutions. Brainstorming is most effective when conducted by a diverse employee pool that can provide different perspectives.

breakdowns

A malfunction that prevents a component or process from operating correctly. Breakdowns usually result in maintenance expenses and lost productivity.

calibrated

To be compared and adjusted to a device with known, standard accuracy. Correctly calibrated machinery and other equipment help eliminate any unwanted variation.

check sheets

A quality control form that uses marks to collect and record information about a problem by tracking categories and occurrences. Check sheets are typically simple forms that can be filled out on the shop floor, but they may also be produced by smart technology.

condition data

The information collected about the health and operating status of equipment. Condition data, including information about vibration levels, temperature, and pressure, can be used in early identification of failures.

confidence levels

A statistical indication of how certain a prediction, estimate, or analytical result is. Confidence levels represent the percentage of times that a calculated result will fall within expected parameters.

confirmation

The process of verifying that data, observations, and predictions accurately reflect real-world conditions. Confirmation of data identifies inaccuracies before they impact decisions that lead to wasted time, effort, or money.

continuous improvement

CI. A lean manufacturing concept that describes an ongoing effort to make products, services, or processes better. Continuous improvement identifies opportunities for improvement, takes action to achieve improvement, analyzes the results, and implements workable solutions.

control charts

A graph used to show trends in data over a period of time. Control charts include a center line and upper and lower limits between which the process should perform.

cycle charts

A type of visualization that displays the amount of time needed to complete a process or task. Cycle charts compare expected cycle time to actual cycle time.

cycle times

The actual time it takes to perform a task and forward it to the next step. One of the major goals of lean manufacturing is to match cycle time to the pace of customer demand.

cycle times

The time it takes to perform a task and forward it to the next step. Cycle times are often tracked and monitored through data collection to optimize efficiency.

dashboards

The centralized screen of an application that visually depicts key information and statuses. Dashboards allow users to quickly access information, such as job progress, machine status, and alerts.

data

A collection of numbers, information, and values about a process or product. Data can be quantitative, such as employee badge numbers and batch totals, or quantitative, such as descriptions of defects or descriptions of activities.

data analysis

The process of performing various calculations on organized information to gain new insights. Data analysis, sometimes called data analytics, helps manufacturers determine courses of action they might take to continuously improve their operations.

data collection

The process of gathering information. Data collection often uses a combination of human observation and tools, such as smart sensors, barcode scanners, and machines connected to the Industrial Internet of Things.

data visualization

The graphical representation of digital information through charts, plots, graphs, and other means. Data visualization allows personnel to interpret data more easily.

databases

A computer storage system that holds data and organizes information. Databases are easily searchable.

defect

An imperfection in a part that prevents it from operating correctly. Defects can lead to reworked or scrapped parts, which increases the cost of a manufacturing operation.

deterioration

The gradual decline in condition or performance of equipment, processes, or quality over time. Deterioration is a sign that maintenance is needed.

diameter

The distance from one edge of a circle to the opposite edge that passes through its center. Diameter measures a circular object at its widest point.

downtime

A period of time during which production stops, often due to mechanical failure or maintenance needs. Downtime reduces the efficiency of a manufacturing operation and should always be limited as much as possible.

efficiency

A measure of the work output of a system versus the total energy input. An efficient system is able to convert a greater amount of the supplied energy into the intended useful work.

error codes

An alphanumeric message that references a specific cause of malfunction. Error codes typically appear on a human-machine interface (HMI) and can be cross-referenced in the individual equipment’s manual.

escalate

To raise an issue, concern, or abnormal condition to a higher level of authority or expertise. Escalating ensures that problems are addressed quickly by involving the appropriate personnel.

failures

The complete loss of performance in a component or a system. Failures can result from electrical and mechanical faults within a system.

fault

A problematic condition that interferes with a component or system’s ability to function as intended. Faults may lead to failure and safety risks.

fishbone diagrams

A visual chart that identifies and isolates potential causes of a problem. Fishbone diagrams list the problem in the center with the 6M categories branching off it, with possible causes branching out further from these.

forecasts

A prediction of demand patterns for a product, which is used to calculate future inventory levels. A forecast typically results in more accurate estimates when ordering raw material and other supplies.

histograms

A visual graph that shows the frequency of a range of variables. Histograms are typically used to measure distribution patterns.

historical

A type of data that is collected and stored over time. Historical data can be used to train digital optimization models.

in-line inspection

The examination of a product during the production process. In-line inspection is an efficient way to inspect parts.

inspection

The examination of a part during or after its creation to confirm that it adheres to specifications. Inspection tools include gages, calipers, and micrometers.

instability

A condition in which a process operates inconsistently or produces unexpected variation. Instability leads to increased defects and equipment failures.

interpret

To examine data and determine what it means. Organizations interpret data in order to determine whether processes are performing as expected.

kanban boards

A visual tool that uses cards organized in columns to track the flow and status of different tasks in a process. Kanban board cards are often color-coded by type of work.

logs

A record of system or machine activities. Logs store data that can help to troubleshoot problems and verify activity.

lower control limit

LCL. A control limit on a control chart indicating the boundary for the minimum permissible value. The lower control limit helps identify if there is any significant decrease in variation or if the process is not meeting the desired standards.

maintenance

Any activity that contributes to the care and upkeep of machines or equipment. Maintenance tasks include cleaning and lubricating machines, monitoring equipment for problems, and fixing a machine after it breaks down.

metrics

A measured variable that indicates the performance and status of a process. Metrics can indicate cycle times, defect rates, and other information.

millimeter

mm. A unit of length measurement in the metric system. One millimeter is equal to 0.1 centimeters metric and 0.039 inches English.

motor

A machine that converts other forms of energy into mechanical energy. Motors often transform electrical energy into mechanical energy.

natural variation

A deviation that is normal and expected. Natural variation, also known as common cause variation, cannot be traced back to a single source.

oil

A slippery fluid commonly used as an industrial lubricant. Oil is often used in high-speed applications.

outliers

An input or output value in a data set that falls outside of the normal value range that the rest of the data falls within. Outliers in data sets can indicate inaccurate data or anomalies that require further analysis.

output

The quantity of work an employee or team produces in a given amount of time. Output is a key metric in measuring productivity.

overall equipment effectiveness

OEE. A lean metric that measures how effectively equipment is being used. Overall equipment effectiveness can be calculated by multiplying the number of defect-free parts a process produces by the ideal cycle time and dividing the result by the planned production time.

Pareto charts

A bar graph used to identify the causes of problems that occur most frequently by distinguishing a problem’s major factors from its minor factors. Pareto charts support the Pareto principle, which states that for most events, approximately 80% of the effects result from 20% of the causes.

planned production

The amount of output that an operation expects to produce over a specific period of time. Planned production is compared to actual production to identify delays, downtime, and performance issues.

predictive analytics

The use of data to predict future events. Predictive analytics allows manufacturers to make informed decisions to address things like future supply needs, machine maintenance, and customer demand.

predictive maintenance

PdM. A maintenance approach that involves collecting data in order to anticipate and correct potential issues before they arise. A predictive maintenance approach involves performing maintenance before failures occur to prevent unscheduled downtime and reduce the labor, cost, and time needed for repairs.

pressure

The amount of force applied on an object. Pressure is calculated by dividing force by the area.

probability

The likelihood that a particular event will happen in the future. Probability can be expressed as a fraction, ratio, or percentage.

probability-of-failure

POF. An estimate of how likely equipment or components are to fail within a certain period of time. Probability-of-failure helps organizations prioritize maintenance activities.

production counts

The numerical record of how many parts were produced in a given period of time. Production counts are entered into digital systems to maintain clear records.

production flow

The movement of materials, products, and work through a process from start to finish. Production flow is often depicted using dashboards and other visualizations, which can help identify bottlenecks.

qualitative

A type of data that measures the descriptive characteristics of a part or process. Qualitative data typically includes any non-numeric data.

quality

Conformance to a set of standards or specifications that results in customer satisfaction in a product or service. Quality products are free of defects and meet the requirements of their anticipated use.

quantitative

A type of data that measures the numerical characteristics of a part or process, such as measurements or quantity. Quantitative data typically includes anything that can be counted or measured numerically.

ranges

The difference between the smallest and largest values in a numerical set. Range shows the amount of variation in a dataset.

real-time

A type of data that is captured in the present moment. Real-time data, sometimes called telemetry data, is used to detect problems in a production process before personnel can recognize the issue.

remaining useful life

RUL. An estimate of how long a machine or component can continue to operate safely and effectively before it fails or requires maintenance. Remaining useful life is calculated using condition data, historical trends, and operating context.

rework

An action taken on a nonconforming product or service to make it conform to requirements. Rework is necessary when a part is not produced within the correct tolerances or has defects.

root cause analysis

A study undertaken to find the original or underlying cause of a problem. Root cause analysis involves collecting and analyzing data to determine the true cause of a problem.

root causes

The true origin of a problem, as opposed to any resulting symptoms or effects. Troubleshooting attempts to determine the root cause in order to create a permanent solution.

run times

The length of time a program or process takes to execute. Run time is monitored to draw conclusions about productivity and equipment wear.

run-rate charts

A visual tool that shows how quickly production occurs over a period of time. Run-rate charts identify unusual spikes or drops in production.

scatter plots

An analysis tool that uses the clustering of plotted points. Scatter plots are used to determine if the increase or decrease of one variable is related to an increase or decrease in another variable.

scrap

Any material or part discarded because it does not meet product specifications. Scrap increases waste for the manufacturer.

sensors

A device that detects a change in a physical stimulus and turns it into a signal that can be measured or recorded. Sensors may be connected to a machine or system in order to collect operational data that is later analyzed.

shafts

A cylindrical bar used to support rotating components in a mechanical system. Shafts also transmit mechanical energy and motion.

signal path

The route information takes through a system. Signal paths identified in data logs can be used in troubleshooting.

software

The programs and instructions that control computer hardware functions and operations. Software helps automate production, manage supply chain, and optimize operations to increase efficiency and reduce waste.

stability

The tendency of a process to run in an even, predictable, and controlled manner over time. Stability may result in expected variation, but it does not display unexpected shifts or unpredictable patterns.

statistical process control

SPC. The use of statistics and control charts to measure key quality characteristics and control how related processes behave. Statistical process control helps to identify problems before they can escalate.

status

The current condition of a task, process, or machine. Status may be indicated by color, such as green suggesting working condition and red suggesting a stalled machine.

status boards

A method of tracking tasks or projects and communicating their status to employees. Status boards often contain before and after photos or details about current and future projects.

structured

A type of data that is highly organized and follows a consistent format. Structured data may appear as datasets that can easily be stored in a database.

symptoms

A sign that a process or operation did not work as expected. A symptom is a sign or aspect of a problem but not the problem itself.

telemetry

A type of data that is captured in the present moment. Telemetry data, sometimes called real-time data, is used to detect problems in a production process before personnel can recognize the issue.

throughput

The amount of work or number of parts a machine or production system can complete in a given period of time. Throughput measures productivity and efficiency in a manufacturing environment.

time stamps

The recorded date and time an event occurs. Time stamps are typically tied to an employee’s number for traceability.

traceability

The ability to verify the history, application, or location of an item using data. Traceability throughout the entire product lifecycle can be ensured by the data from automatic identification technology.

trend lines

A line in a chart that shows the general direction of data over time. Trend lines point upward to indicate positive growth and downward to indicate decline.

trends

A general direction in which something is developing. Trends indicate changes in data over time.

troubleshooting

A systematic approach to solving problems quickly and efficiently. Troubleshooting often involves a logical process of elimination to identify the source of a problem.

unplanned downtime

An unexpected stop in production due to maintenance, mechanical failure, or other processing problems. Unplanned downtime can lead to safety problems and production losses.

unstructured

A type of data that exists in its original format. Unstructured data is raw data in the form of files, images, and text.

upper control limit

UCL. A control limit on a control chart indicating the boundary for the maximum permissible value. The upper control limit helps identify if there is any significant increase in variation or a potential issue that needs investigation.

validate

To demonstrate that a specific process, method, piece of equipment, or system consistently produces a product meeting its pre-determined specifications. Validating manufacturing events ensures that products are consistently produced and controlled according to established standards.

vibration

A rapid, continuous, repetitive motion in a machine or other structure. Vibration can negatively affect mechanical operations.

vibration chart

A visual tool used to evaluate the mechanical health of rotating equipment. Vibration charts compare expected metrics against a machine's speed or frequency to determine if it is running properly.

vision systems

A collection of advanced optical components that collects data and forms an image, which is interpreted by a computer. Vision systems can be used to measure and inspect manufactured parts using the collected image data.

wear

The erosion of material as a result of friction, use, or environmental conditions. Wear is often caused by two or more objects rubbing or sliding against each other.

work orders

A request issued within a company to produce a specific quantity of material within a certain timeframe. Work orders can be viewed on digital systems such as manufacturing enterprise systems (MES) and computer maintenance management systems (CMMS).