Data Analysis to increase OK output

Maintenance costs often skyrocket because the root causes of downtimes are not eliminated and the downtime losses have to be made up for by overtime work or by keeping additional reserve capacity on standby. To enable you to effectively tackle the actual causes of downtime, Legato Sapient analyses every process step in real time, systematically evaluates machine and production data and aggregates these into meaningful key figures, such as for OEE (Overall Equipment Effectiveness), MTTR (mean time to repair) or MTBF (mean time between failures).

TopX evaluations of machine downtimes and their causes reveal potential for improvement, which can then be successively implemented. Causes of problems can be tracked directly and eliminated via the integrated control of actions and measures — fully in line with the continuous improvement process (CIP). This means that in future, your day-to-day business will be determined by preventive actions and no longer just by problem-driven reactions.

Data that creates business value

Production KPIs create transparency. The module of our MES software solution, Legato Sapient, enables the automatic calculation and aggregation of information. The insights generated in this way allow process deviations to be identified and resolved more quickly.

By using our software solution, you can increase your production results by at least 3% — results that can bring additional millions! The increase in OEE is based, for example, on an increase in availability through a shortened response time in the event of a malfunction, and the analysis of historical data for optimized action and measure management. Real-time monitoring with regard to buffer levels and system interlinking can also help to avoid idle times, which in turn can lead to an additional increase in output. An optimized cycle time based on a reduction of cycle time overruns as well as the smoothing out and minimization of cycle times also saves valuable minutes, which in turn helps to improve output.

Legato Sapient: Your system for the long-term improvement of OK output

The information base for collecting data is the machine connection, and both homogeneous and heterogeneous machine parks can be connected via different kinds of communication. It is irrelevant which machine manufacturer your production machines are from — over 2,000 machines can be connected to one system!

The collected data is then aggregated into meaningful key figures, such as output, quality level, plant availability, MTTR, MTBF and many more. Target and limit values can be set for each key figure, so that constant monitoring of the actual status of the target value is possible. All information can be accessed via a standard web browser. To ensure the best possible understanding, both tabular and graphical evaluations are available to show the key figures.

Our software solution enables you to evaluate standstills within the framework of, for example, reporting histories or the top 10 evaluations. Using these, you can first look at the faults that have caused the biggest problems (downtimes) within the scope of the CIP. With the successful elimination of the causes of malfunctions, recurring interruptions can be avoided in the long term.

Furthermore, our software offers dedicated action and measure management for the systematic and continuous processing of various activities, such as the ongoing avoidance of recurring faults and interruptions as described above. For this purpose, measures can be created directly in the system for various events, which can then be tracked within the scope of CIP with a due date and responsible area. This simplifies team communication and cooperation significantly, as everyone has an overview of the measures and different subtasks can be assigned to the appropriate experts. What‘s more, this information is used for shop floor management and the morning meetings, which means the depth of information can be increased significantly here as well.

Make optimized decisions in future: Well-founded and fast thanks to clear data analyses in near real time with Legato Sapient.

Advantages at a glance:

  • Greater transparency throughout the entire manufacturing process
  • Reduction of downtime
  • Increase in output


True to the motto “many roads lead to Rome,” there are various starting points in Legato Sapient to improve the OK output in the long term.

Often, we start by looking at meaningful KPIs such as the availability of an area or a plant. In the following screenshot, several areas or plants can be compared with each other via “Multiselect.” In this case, we make a comparison of the output (actual vs. target number of pieces) and the availabilities (total, technical, organizational and system-related):

The “weakest” plant or area, i.e., the “bottle neck,” can be identified using this comparison. On the basis of this, a more in-depth analysis of the causes then takes place.

Typical disturbance evaluations, such as TopX disturbances, are also used. In this way, the main causes can be identified and then eliminated.

This view also serves as a basis for more in-depth evaluation of the causes; typically, disturbance evaluations such as TopX evaluations are used for this again.

The following screenshot shows this kind of a TopX evaluation – the faults shown in red have been identified as particularly relevant, as they have already appeared as top faults over a longer period of time.

Typically, we start with the fault that has the greatest impact on downtime or availability. In action management, a corresponding action with responsibility and a target date is defined and processed. Subsequently, the “second most important” malfunction is dealt with in the same way.

A typical representation, a Kanban board, with all open measures is shown in the following screenshot:

To increase the OK output, it is of course also elementary to avoid or keep the number of rejects low.

The following screenshot shows the relationship between reject and OK piece counts.

For further action, the causes of the rejects must be known. Click on a red pie slice, and drill down via the 3 dots at the top right to open the corresponding piece count history in the sidebar.

From this, a further drilldown can then be made to the associated faults.

The main causes (malfunctions) are then controlled again by creating a measure in the measure management.

In addition to considering availabilities and quantities, further key figures (e.g., cycle times or energy values) are used to increase the OK output.

The following example shows a typical display or evaluation of cycle times, which helps detect disturbances in the process. In the lower area, each point represents a cycle time – all points that are not in the green-yellow band are cycle time overruns above the limit values. In each case, there are disturbances in the process.

As part of the further analysis, the diagram is “zoomed” into the affected time range, and then a drilldown is performed (via the 3 points, at the top right of the boardlet) into the fault messages of the affected time range. In order to avoid such malfunctions in the long term, an action can then be created in the action management as already described above.