Frequently Asked Questions

Q.1: How many sensor is required to calculate the OEE? Should the Total count and Good count sensors be installed in the same machine?

Ans. 1 Sensor – (Partial OEE or full with manual reject entry) Vorne will provide all supported KPI’s except OEE Quality. You can still get a full OEE score by manually scanning reject barcodes or manually entering rejects if necessary.

2 Sensors – (Complete OEE – automatically calculated) Vorne will automatically calculate a full OEE score based on the user providing 2 of the 3 required inputs (In Count, Good Count or Reject Count). E.g. Most clients will provide an In Count (total) and a known Good Count in which XL will automatically calculate the rejects as (In Count – Good Count = Reject Count) etc.

Q.2: Since we do not calculate Quality, will the Vorne system will the Good count for Performance calculation? [ In such a case only 1 sensor is sufficient for the calculating OEE]

Ans. 1 Sensor deployments will assume that the In Count (total) = Good Count. Your OEE score will therefore be the product of Availability x Performance where Quality is always assumed to be 100% since it is not a tracked or calculated metric.

Q.3: What is the Reliability and life of the Vorne XL 810-1 unit? In case there is a malfunction in the unit is there a visual indication/ alarm?

Ans. International warranty is 1-year. Expected functionality is 10 years without the need for any scheduled maintenance. Support pages have diagnostic pages for memory consumption or error codes within the system.

Q.4: In case of power failure to the CPU unit will system get reset and the data lost? [ Is there a back-up memory which helps to start from where the power failed?]

Ans. Both configured settings and historical production data is saved to non-volatile memory meaning it will be fully retained despite removing power to the display. Both configuration and production data can be backed up manually (options to automate this as well) for any recovery needs that may arise.

Q.5: If the Vorne XL unit breakdown can we enter the data manually in the software later?

Ans. No.

Q.6: Is the display on shop floor scrolling to display other KPI required OR is fixed?

Ans. The XL810-1 can display up to 8 total scoreboard KPI’s. It would rotate back and forth between two screens every 5 seconds showing 4 metrics on each page.

Q.7: Will the Target bottles for the day and the current filling count gets displayed on the shop floor?

Ans. Yes. This is supported

Q.8: Can the ‘Quality’ display on shop floor and in the software be masked or removed? [ Quality is not part of Client’s OEE calculation. Client considered only Good count for OEE calculation.]

Ans. Yes, as Quality is simply held at a constant (100%) and is therefore not a factor in the OEE calculation since In Count will equal Good Count in this situation.

Q.9: What-If line is operated bypassing the Vorne XL system?

Ans. XL will not record production data unless it is receiving active cycle inputs. If you have a process in which production is running, but it does not provide cycle inputs to the XL system and you want to track it, further discussion will be required to evaluate whether we can track this secondary process or not.

Q.10: Can we get individual equipment wise OEE in the reports by installing multiple sensors at equipment level?

Ans. No. Vorne XL runs under the simplified assumption that we can monitor an existing production line by monitoring 1 point on the line (the constraint). By way of barcode scanning/using software Downtime Reasons, we provide further insight and clarity as to what specific processes, assets or machines etc. are causing downtime and inefficiencies. But OEE is calculated for the overall line itself, not individual machines at this time. (Vorne is working on a new hardware platform called OEE Step that will allow an OEE score for multiple assets on a single production line but this will not be available until potentially 2025+).

Q.11: What is the storage duration for all data & reports? [ Memory capacity?]

Ans. 4 GB of data which in practice translates to approx. 3-5 years of rolling historical production data for most XL users. This can vary by use case of course. If nothing is done to back up the data, once XL reaches the data limit, the oldest data is replaced by the incoming data in a cyclical fashion.

Q.12: Are reports configurable and to what extent? [ Highlight what cannot be changed?]

Ans. Built-in reports are “configurable” meaning we can edit parameters such as the specific KPI’s being reported, the dimensions in which the data is portrayed, the timeframe over which the data is pulled, whether the data is for a single asset or aggregated over multiple lines etc. Users can save their own “views” so their custom pages can be used moving forward. Additionally, XL also includes a completely customizable reporting platform called Dashboards in which you have complete control over building your own reports or dashboards. This can be related to PowerBI or Tableau for example in custom reporting behaviour and will automate many of your production reporting needs.

Q.13: Can the Plan data / Ideal cycle time date be correct later if there is an error in entering the information?

Ans. The ICT and Takt Time configured for a Part can always be edited or corrected moving forward, however, we cannot go back and edit a previous part run with updated parameters. Adjustments will only impact future part runs.

Q.14: Are downtime reasons configurable as per Client’s requirement, nomenclature & acronyms used?

Ans. Downtime reasons are configurable but limited to 24 characters

Q.15: Is communication with Filler’s PLC possible to pick-up required data? [ How does the system integrate with – PLC, HMI, SCADA, ERP, OPC? – what type of signal exchange is possible?]

Ans. See Tech Note TN000308. XL requires a 5-24 VDC signal that can come from virtually any sensor such as a photo-eye, proximity switch, relay, dry contact, encoder, or output from a PLC. For the PLC specifically, we are typically requesting a hardwired output signal from the PLC. We can use OPC DA for cycle times >1s. We also can stroke the inputs via our REST-based API or via an HMI (some of which require integration software like PLC Data Link Software, XL Bolt-On OPC Server Software or Bolt-On HMI Software – Basic – Command and control XL via touchscreen, tablet or PC

Q.16: Can we incorporate individual equipment ‘Fault status’ in the Vorne system using relays e.g. if a line equipment stops due to any fault, Vorne gets that signal that the particular equipment has stopped due to a technical fault.?

Ans. Vorne can be configured in either Automatic or Manual Run Detection. Automated Run Detection would not require relays to provide a fault status as Vorne automatically assumes the process has stopped based on an absence of cycle inputs (called the downtime threshold). E.g. if XL does not see a “cycle” within 5 minutes, XL will enter a Down state and require a reason be scanned. Manual Run Detection requires an explicit signal from a source such as a PLC in order to dictate when the process is running vs. when it is down.

Q.17: Can the ideal cycle time value be changed based on the packet and volume to be filled based on filler speed?

Ans. Yes. This is fully supported in what is called the Parts and Run States page in which you can configure such parameters by Part ID.

Q.18: How to handle Reworks so that it does not adversely impact the OEE calculation

Ans. Rework can be handled in various methods depending on the need. Reworked product would not hit the Quality score as they are making their way back into finished goods, however, you would see this loss expressed in your OEE Performance as it took 2x the time to produce etc.

Q.19: Is the Shift timing & working, non-working days configurable?

Ans. Yes.

Q.20: MTBR and MTBF definition and calculation to be established and aligned

Ans. MTBF – How long on average the process runs before it is stopped by a fault (Mean Time Between Failures). Calculated as Run Time / Down Events.

MTTR – How long on average it takes to get the process running once it is stopped by a fault (Mean Time to Repair). Calculated as Down Time / Down Events.

Q.21: How is simultaneous breakdown of multiple equipment at same time accounted in the system?

Ans. XL does not track downtime in parallel. You can however split downtime events. For example, the line is down for 5 minutes for Reason A. Once fixed, the line is still down in which case you can end the first down event and start tracking a new down event thereafter for Reason B. There is no limit to consecutive downtime events being recorded.

Q.22: How is the production data backed -up? What is the back-up limit? If the Vorne XL unit breakdown can we retrieve the past data and information?

Ans. 4 GB of data which in practice translates to approx. 3-5 years of rolling historical production data for most XL users. This can vary by use case of course. If nothing is done to back up the data, once XL reaches the data limit, the oldest data is replaced by the incoming data in a cyclical fashion.

Q.23: Does the unit need any Software updates? If yes, how are updates done?

Ans. Software updates are available FREE from Vorne but are not required (although strongly recommended). XL can be configured from an IT networking security standpoint to either have the ability to check for updates automatically or be completely isolated from any outside networks or servers in which case Vorne will provide a secure link to download the file remotely for more of a manual update if necessary.

Q.24: cade of software or hardware issues, can it be addressed locally / online OR the unit has to be sent back to Vorne USA?

Ans. IIOTEXPERT as Vorne’s strategic partners hold stock of the XL displays as well as common repair components. The first response will always be for the local partner to address the failure. Support from the US would be complementary if necessary.

Q.25: In case of a fault in the line, if the Line is run at slower speed for observation during trouble shooting, how will the Vorne system capture this loss reason?

Ans. This can be captured as Performance Loss (running slow) OR alternatively can be logged as Availability Loss if you scan into a specific planned downtime event to record this. Most common is the former (Perf. Loss – Running Slow).

Q.26: Can efficiency of Machine/Line show more than 100%?

Ans. Yes. Efficiency = Good Count / Target Count

Target Count: Real-time target for good pieces. Each time the TAKT time elapses the target count increases based on the Target Count multiplier. The Target Count will increase during planned production time (Run Time + Down Time) and will pause during not scheduled and planned stop time. TAKT time mirrors the rate at which meets customer demand.

Q.27: I see 90 days’ free trial of Vorne XL on Vorne website. Can I avail this option here in India?

Ans. Yes. But you need to pay only custom duty, shipping cost etc. as mentioned on Trial Quotation from IIOTEXPERT.

Q.28: Can you do POC in my factory?

Ans. Yes. But you need to reimburse engineers visit travel cost, accommodation and local transportation charges on actual for visiting your factory site. This amount will be adjusted in purchase order amount if we get order from you.

Q.29: Do we need to sign NDA before POC?

Ans. Yes. There is one NDA format you need to sign for the cause of data and technology privacy copyright.

Q.30: Can you visit my factory for evaluation and feasibility check of our machines/process before we make the order?

Ans. Yes. We can make the visit but as per our company policy more than 100 km travelling from Haridwar India you need to reimburse engineers visit travel cost, accommodation and local transportation charges on actual. This amount will be adjusted in purchase order amount if we get order from you.