Manual entry of causation information leads to data accuracy issues as events are often left unjustified, which skews OEE metrics and results in incomplete loss data. With automatic causation, we collect causation data automatically from industrial control systems with the help of a 3rd party software called Kepware KEPServerEX. Automatic causation can significantly reduce the number of unjustified downtimes and therefore improves the accuracy of OEE metrics and loss data.
Automatic causation is enabled by the ability of Kepware KEPServerEX to read data from PLCs. A PLC is a small computer in the production line that is able to produce data, such as sensor readings or in this case, fault codes (or both). These fault codes are what informs the ioTORQ Lean system of the causation information.
Information channels called "tags" are defined in the PLC system. Within each "tag", specific fault codes can be emitted in order to report specific events such as a breakdown or an electrical issue on a production line. This fault code can be sent to the ioTORQ LEAN application through the internet and be used to justify a current downtime event.
An asset defined in ioTORQ LEAN may be associated with several PLC tags, and may have many fault codes mapping to many downtime causes.
When automatic causation is enabled, if a downtime is detected on an asset, then the system verifies if a known fault code was emitted recently in the PLC system. If that's the case, then the corresponding cause is used to justify the downtime. If nothing was emitted or if the last fault code is too old to be related to the current downtime, then a notification is shown to the operator so that they can enter the cause of the event manually.