Vorne XL is a comprehensive production monitoring platform that includes:
▪ XL Productivity Appliance™: IoT devices that each monitor one manufacturing process. XL
devices are unique in that they work equally well as networked devices in your internal network or as
edge computing devices connected to XL Enterprise.
▪ XL Enterprise: A cloud-based application developed by Vorne that provides services that extend the XL platform. These services include alerts (real-time email alerts), reports (automatically delivered
end-of-shift reports) and updates (software updates delivered to XL devices).
Software Updates :
Software updates for XL devices are digitally signed and hosted on XL Enterprise (they are also available from our technical support team). If enabled, XL devices automatically check for updates once per day.
When a new update is available, the XL device automatically downloads it – ready for the administrator to install at a time of their choosing.
XL Enterprise software updates are managed by Vorne and are transparent to users.
XL devices are highly integrated embedded systems with a TI Sitara™ ARM processor and 4 GB of eMMC Flash (storing approximately one year’s worth of historical production data). The OS is a Yocto-based Linux distribution designed for embedded and IoT devices. The application software includes an integrated database and web server. No software needs to be installed in your existing infrastructure. Every XL device uses the same data model and software, and from an IT perspective is managed the same way.
XL Enterprise is a cloud-based application hosted on Amazon Web Services using data centers located in the USA. XL Enterprise temporarily stores production data – no historical production data is stored.
XL supports IE 11, Edge, Chrome, and Firefox browsers. Chrome is recommended for best performance.
XL is the simplest, fastest, and most powerful way to monitor and improve manufacturing
XL is a standalone device that includes I/O to communicate with your process, a scoreboard for your operators, and built-in reporting for your managers. And – it seamlessly scales from machine to enterprise.
XL works on any discrete manufacturing process. That’s one of the reasons it’s used on 30,000+ installations in 45+ countries. Here’s a few more:
"Our CEO personally came in and saw how big of an impact XL had made. He was amazed at the gains it provided compared to the cost. We were considering a trial of another system – but the cost of the trial exceeded the cost of outfitting our entire plant with XL!"
M.C. | Industrial Automation Engineer | Global Confectionary Manufacturer
Online Technical Support = $0
Maintenance Contracts = $0
Monthly Fees = $0
Fees for additional users = $0
Software upgrade = $0
Data Storage fees =$0
Total Extra Fees = $0
on-site local offline support is chargeable
Overall Equipment Effectiveness (OEE) identifies the percentage of planned production time that is truly productive. An OEE score of 100% represents perfect production: manufacturing only good parts, as fast as possible, with no down time.
Traditionally, OEE lives in offices and meetings. What do we mean by that? Operators capture data using log sh
XL is used on over 25,000 manufacturing processes in 45+ countries and consistently has been recognized for exceptional outcomes on its IOT based quick solution on computer and on your mobile phone on a real time basis.
Reports -Full-featured reporting with customizable dashboards. All data is available for instant export to Microsoft Excel.
Built-In Reports - Andon, Down Time, OEE, Six Big Losses, TEEP (Hidden Factory), Changeover, Speed Loss, Rejects
Analytics - Advanced Analytics, Top Losses, All Production, Total Production Timeline, Asset Timeline
Custom Dashboards-Chart (Pareto, Line, Column, Cluster, Stacked Column, Stacked Pareto), Table (Tabular, Hierarchical), Chronogram, KPI, KPI Group
Metrics - XL includes 105 metrics (available both in real-time and for historical analytics) within 11 groups: Counts, Cycles, Rates, Production Times, OEE, Six Big Losses, TEEP, Quality, Target, Goal, and Labor
XL is a platform for improving manufacturing productivity. The most important feature of XL is EASY. Our goal is nothing short of making it incredibly easy for you to improve manufacturing productivity.
Our newest software (version 2.0 and higher) runs on an entirely new hardware platform, with an order of magnitude increase in processing power and an entirely redesigned data model. For existing XL customers, drop-in hardware upgrades are available; however, data and configuration are completely new, so they do not port across. XL units on the previous hardware platform can be upgraded .Read below about latest release features.
Instantly add comments to any production event, such as a down event, changeover, or part run. Simply click on any chronogram event to add a comment.
Our new comments feature works great in combination with another newer XL feature – heat map chronograms. Scan for “red” events and make sure each such significant event has a comment.
Use comments to add context to a reason, explain what went wrong, describe how you addressed a problem, or add to the conversation with a reply. Capture details that add value to review meetings or to deep analytics for improvement programs.
Analyze comments to identify followup and improvement actions – or simply to verify that your team is following your policies for capturing comments.
The new View Comments page is perfect for exploring comments. Select a built-in view or search for one or more words, such as OEE or conveyer jam. Gain further insights and context with single-click access to a complete loss report for each and every event.
Or, create your own views. Focus on a specific type of event, such as down events or changeovers. Or look at all comments that occur during a period of time – such as a shift or part run. Add filters to refine your view. Create views that align to or verify company policy, such as:
Organize the hierarchy of all your work centers, and how they roll up, in one place – XL Enterprise.
We’ve completely redesigned our tables and packed them full of new features.
Refine your analysis with our new advanced filter control. XL now supports filtering on both dimensions and metrics, including support for complex filters with multiple dimensions and metrics.
Examples of filters you can build include:
It can be very useful to ignore or recharacterize counts when production is in a certain state, such as running rework or in a changeover. You can now do just that by:
Configure any digital input to suspend all count and cycle inputs. This provides an automatable hardware-based mechanism for ignoring counts. For example, you may want to ignore all counts while running rework.
Configure any Planned Stop or Not Scheduled reason to ignore all counts or to categorize in counts as rejects. This provides an automatable state-based mechanism for ignoring or recharacterizing counts. For example, you may want to classify all counts as rejects while in a changeover.
Now you can easily use your network proxy server as an intermediary between XL and XL Enterprise. For example, if your network firewall only supports static IP addresses, a proxy server can be used to provide DNS lookup and automatically manage connectivity to XL Enterprise.
Configure XL with a proxy server type, proxy server address, and proxy server port. Supported proxy server types include HTTPS, SOCKS (socks4, socks4a, socks5, socks5h) and HTTP with CONNECT tunneling.
Using color to visualize metrics is extremely effective for quickly spotting areas of concern – or areas where you are doing exceptionally well.
Normalized metrics (i.e., percentages) have heat map colors automatically generated from their metric alert ranges – spanning from red to amber to green. Other metrics are automatically generated in shades of red (e.g., Reject Count), green (e.g., Good Count), or blue (e.g., Total Count).
Choose from four different types of heat map charts: time (e.g., OEE over Time), dimension (e.g., OEE by Part), dimension over time (e.g., Utilization by Plant over Time), or dimension by dimension (e.g., Labor Efficiency by Asset by Team).
We have completely redesigned the chronogram – with a huge array of new features:
The KPI and Chronogram elements now feature “live” controls. Live controls provide the shortest distance between your imagination and your dashboards by showing instant changes to elements as you make selections in their controls. You will love how easy this makes chronogram configuration – especially with their many new features.
One of the most popular features in XL is automatic run detection, which continuously monitors the cycle input to detect if the process is running or down. For processes with long cycle times, it can often be better to control run detection from an external source. Now XL provides three ways to externally control the run detector:
When a break or changeover ends, there is often a short period of time before running production can be detected. XL now assigns a temporary production state to this time and displays “Detecting… Run or Down” on the scoreboard to let the operator know that XL is automatically detecting the state. As soon as XL detects that the process is running or down, the scoreboard updates with the new production state and XL automatically adjusts the underlying event.
Delve deeper into changeovers with reason analytics. We’ve updated the Changeover deep dive page to include:
XL also now includes an option to start changeovers via digital inputs to ease integration with other systems.
We’ve made reject reasons a full-fledged analytics dimension. This means they are available throughout the reporting interface, including custom dashboard tables and charts.
We’ve also added new out-of-the-box charts to the Quality Loss deep dive page, including the ability to analyze rejects by production phase, production state, and shift.
Your team can now receive an instant end-of-shift summary report from XL Enterprise with key metrics, comprehensive loss information, and a summary of all part runs for that shift. The report includes:
It is easy for team members to subscribe and for your entire team to work from the same set of timely and accurate information.
If your mobile carrier supports email to text message gateways, you can now choose to receive alerts (real-time notifications based on metrics, production state and targets) as text messages instead of emails.
Please note that not all carriers provide this service and some carriers only provide it as a premium service (e.g. Verizon). Also, message and data rates from your mobile carrier may apply to text messages sent by XL Enterprise.
Automatically send email alerts to key employees based on how your process is running. Alerts are delivered by XL Enterprise, which makes it easy to create automatically escalating alerts based on:
XL Enterprise is a cloud-based SaaS application developed by Vorne as an integrated part of the XL platform.
XL now calculates earned labor time and labor efficiency based on target labor times you define for each part. Instantly know if you are meeting or beating your labor standards.
We’ve also updated the Teams and Labor page to make it immediately apparent when you are NOT meeting your labor targets for one or more parts. We also show you labor efficiency over time, and provide tools for comparing the effectiveness of your teams. Or – create your very own dashboard reports.
Many companies train their operators to scan rejects into XL in order to include operator-provided reasons for each reject.
Now XL makes this even easier with a new feature that enables operators to scan multiple rejects. Simply scan the number of rejects followed by the reject reason to include them in the current shift and part run.
XL now performs run and down detection based on the cycle input. This has a number of advantages – especially for applications where cycle speeds vary greatly by part.
Speed-based detection enables you to define running as a percentage of top speed sustained across a configurable number of cycles. Since XL calculates top speed from Ideal Cycle Time, run detection automatically and seamlessly adapts to each part you run.
TEEP (Total Effective Equipment Performance) provides insights as to the true capacity of your manufacturing operation. It takes into account both Equipment Losses (as measured by OEE) and Schedule Losses (as measured by Utilization). It measures the percentage of all time that is truly productive. XL now measures TEEP, Utilization, Capacity Loss, and Capacity Lost Time.
We’ve reimagined the Six Big Losses, making them easy-to-understand and comprehensive in capturing your losses. Every loss is automatically categorized as an Unplanned Stop, a Planned Stop, a Small Stop, a Slow Cycle, a Startup Reject, or a Production Reject. Losses are available as percentages or time, and can be viewed from different perspectives, such as Shift, Job, Part, Hour or Process State.
XL now provides comprehensive quality analytics, with a reject reason logged with every rejected part. Reject reasons can be logged through digital inputs or barcode scans. An unlimited number of reject reasons can be configured and the resulting data can be charted, trended, and more.
XL automatically categorizes rejects that occur during changeovers and initial production as startup rejects (as differentiated from production rejects). You can configure the amount of time that is considered “startup” to best match your manufacturing process. This feature further tunes Six Big Losses and makes it easy to gather useful information without operator intervention.
Hour-by-hour boards are particularly popular in automotive and in lean manufacturing. We’ve brought the concept to XL by aligning hour-based reporting to your shift schedules. Compare hours across shifts regardless of time zones or when shifts started.
OEE should be part of a balanced approach to improving productivity. Solely focusing on OEE can encourage teams to overproduce (leading to excess inventory), run equipment beyond rated parameters (potentially leading to safety issues), overstaff processes (reducing labor productivity), or other counterproductive behaviors.
short term Benefits
OEE identifies the total opportunity for improvement (sometimes referred to as “uncovering the hidden factory”) for a given piece of equipment (or process).
Long term Benefits
OEE helps you drive improvement through a better understanding of losses. It also provides an objective way to set improvement targets and track progress towards reaching those targets.XL tracks all the losses and that the true capacity of equipment is exposed.
The scoreboard always reflects the current state of your manufacturing process. It provides your
Operators with contextual information that guides their actions towards “winning the shift”.
When running normally, the scoreboard shows TAED (Target, Actual, Efficiency, Down) so your operators can easily see what they have produced (Actual) and if they are winning the shift (Efficiency of 100%).
If the line goes down your operators are immediately prompted with a message that includes event down time and a reminder to scan a reason. The reason can be scanned any time before the next down event.
When running slow, running poor quality, or running poorly (which is running slow with poor
quality) your operators are prompted in real-time so they can respond immediately.
When a changeover, maintenance, meal/break or meeting starts, your operators are prompted
with a target and remaining time (if so configured) to help them stay on target.
CI engineers love that the Top Losses page tells them exactly where to focus their attention (it ranks and prioritizes every loss). Consider it your continuous improvement roadmap to success. No additional analysis needed. It’s the perfect page for picking your next improvement project.
Deep dive into performance loss and its underlying constituents: cycle loss and small stop loss. Ideal for identifying which parts and shifts are most affected by cycle losses, and for validating your ideal cycle time settings against actual production data.
Join us for a personalized 30 or 60 minute webinar. We'll focus on your equipment, your process, and your challenges.
Call us for answers to all your questions on how we can help you quickly improve your manufacturing productivity
Have a question? We love questions and we love to help. Providing practical solutions to real-world problems
Email : firstname.lastname@example.org
Install Vorne XL and Track your plant productivity real-time