====== 2. System Overview ======

===== 2.1 What is OEE? =====

OEE (Overall Equipment Effectiveness) is the industry-standard metric for how effectively a production line is used. It is the product of three factors:

^ Factor ^ Question answered ^ Losses captured ^
| **Availability** | Did the line run when it should have? | Unplanned downtime (breakdowns, faults) |
| **Performance** | Did it run at full speed? | Slow cycles, minor stops |
| **Quality** | Did it produce good parts? | Scrap, rejects |

<code ->
OEE = Availability × Performance × Quality
</code>

An OEE of 100% means: producing only good parts, at maximum speed, with no unplanned stops. World-class discrete manufacturing is typically considered to be around 85%.

**Pinetek Insight** computes these factors automatically from the counter signals of your line; the exact formulas are documented in chapter [[insight:manual:10-oee-reference|10. OEE Calculation Reference]].


===== 2.2 System architecture at a glance =====

{{.:pasted:20260717-125823.png?300}}


==== 2.2.1 Pinetek Insight application ====

**Pinetek Insight** runs as an app on the Pinebox. It consists of:

  * a backend (data acquisition, state machine, database, report generation), and
  * a web interface served on port ''8000''. No client installation is needed; any modern browser on connected network can access it at %%http://<device-ip>:8000%%. See the connection option in the Pinebox manual: [[pinebox:01_manual:4_configuration:4-1_configuration-update|Pinebox Manual, Configuration Update]] [PBX].

Production data is stored in a MariaDB database on the device itself. Normal operation has no cloud dependency. Data leaves the device only where explicitly configured: backups ([[insight:manual:09-system-administration#backup_restore|chapter 9.3]]), e-mailed reports ([[insight:manual:08-reporting|chapter 8]]) and the AI Assistant ([[insight:manual:06-analysis#ai_assistant|chapter 6.5]]).

==== 2.2.2 Pinebox as data source [PBX] ====

The Pinebox standard software (running in parallel to the **Pinetek Insight** app) is the field-level data acquisition source. It connects to the IO-Link machine sensors and makes the acquired signals available to **Pinetek Insight** in two ways:

  * **Polled services**: the Pinebox exposes counters, timers and cycles as simple network services; **Pinetek Insight** reads them cyclically.
  * **Pushed values**: process sensor values are sent //by// the Pinebox side //to// **Pinetek Insight**'s data interface.

^ Signal ^ Interface ^ Used by **Pinetek Insight** for ^
| Piece counters | polled from Pinebox ''/counter/values'' | Production quantities, state detection, throughput per stage |
| Takt timers | polled from Pinebox ''/timer/values'' | Takt/cycle-time monitoring |
| Machine cycles (energy-based) | polled from Pinebox ''/cycles'' | Cycle stations: cycle duration, energy, stall detection |
| Process sensors | pushed to the **Pinetek Insight** API | Additional analogue/process values (temperature, pressure, speed, …) |

<WRAP info>

**Using more than 4 sensor inputs** In the standard single-device installation the Pinebox services run on the same host as **Pinetek Insight** and are reached at ''localhost:18080''; a Pinebox can equally be addressed by its IP on the plant network. Multiple Pinebox devices can be used; each counter, takt source and cycle station stores its own host/port. The "external" Pineboxes are standard devices without the **Pinetek Insight** app running.

The details for integrating additional Pinebox devices are described in [[insight:manual:11-pinebox-interface#reachability_and_multiple_pinebox_devices|chapter 11]].

</WRAP>

How the signals are wired and configured on the device side is described in the [[pinebox:01_manual|Pinebox Manual]] [PBX]. Chapter [[insight:manual:11-pinebox-interface|11]] of this manual describes exactly which Pinebox services **Pinetek Insight** consumes.


==== 2.2.3 Data flow ====

  - The Pinebox counts parts at each process stage and measures timers/cycles. [[pinebox:01_manual|[PBX]]]
  - **Pinetek Insight** polls the counter values cyclically (see [[insight:manual:11-pinebox-interface|chapter 11]]).
  - The state machine compares current with previous values, detects activity and timeouts, and derives the production state.
  - Every state change is written to the database as a state event; counter readings are stored as time series.
  - When a production run ends, **Pinetek Insight** computes and stores the run's OEE figures.
  - The analysis views, the AI Assistant and the report engine all read from this database.


===== 2.3 The production state model =====

==== 2.3.1 States ====

The line is always in exactly one of seven states:

^ State ^ Meaning ^
| **Stopped** | No production run active |
| **Changeover** | Product change / setup in progress; run is prepared |
| **Running** | Production run active, counters advancing normally |
| **Running Slow** | Run active, but throughput below expectation |
| **Down** | Unplanned stop; counters stopped unexpectedly |
| **Planned Stop** | Deliberate pause (break, planned maintenance) |
| **Draining** | Input stopped, line runs empty before the run ends (no bottleneck detection) |

{{.:pasted:20260727-142232.png?500}}


==== 2.3.2 How counter signals drive state transitions ====

**Pinetek Insight** derives states from the movement of the stage counters [[pinebox:01_manual|[PBX]]]:

  * **Changeover → Running**: production starts when a product is selected and counting begins.
  * **Running → Down**: a stage counter stops advancing for longer than its configured **timeout** (see //Line Config → Program → Stages//, [[insight:manual:07-line-configuration#programs|chapter 7.1]]) → planned/unplanned stop. The state is set by the operator. When counting resumes, the state returns to **Running** automatically.
  * **Running → Running Slow**: throughput falls below the expected rate without stopping completely (one station stalls minimum)
  * **Running → Draining**: triggered manually; the input stage is expected to stop while the rest of the line runs empty. When the output counter times out, the run ends and the state becomes **Stopped**.
  * **Stopped**: ending the run (manually or after draining) always returns to Stopped.

Every period spent in **Down** must be justified with a downtime reason ([[insight:manual:05-live-operation#recording_downtime_reasons|chapter 5.4]]). Time in **Planned Stop** counts as planned downtime and does not reduce Availability.


==== 2.3.3 State events ====

Each contiguous period in a state is stored as one state event with start, end and duration. State events are the basis for the shift timeline ([[insight:manual:05-live-operation#production_timeline|chapter 5.2]]), the state distribution and downtime analyses ([[insight:manual:06-analysis|chapter 6]]) and the Availability calculation ([[insight:manual:10-oee-reference|chapter 10]]).

===== 2.4 Key concepts and terms =====

^ Term ^ Meaning ^
| **Program** | A line configuration: the set of process stages, their counters, sensors, takt sources and detection parameters. Typically one program per line layout or product family. |
| **Product** | An article produced with a program. Carries part number and ideal cycle time. Several products can share one program. |
| **Production run** | One continuous production of one product: from changeover/start to run end. OEE is calculated per run. |
| **Process stage** | One counting point in the line (e.g. filler, capper, packer). Each stage has a role: //Input//, //Output//, //Defect/Reject// or //Intermediate//. |
| **Counter** | A piece counter acquired by the Pinebox and mapped to a stage. [[pinebox:01_manual|[PBX]]] |
| **Takt** | Cycle-time measurement from a Pinebox timer. [[pinebox:01_manual|[PBX]]] |
| **Cycle station** | A machine monitored via energy-based cycle detection (power rise/fall), e.g. a press or moulding machine. [[pinebox:01_manual|[PBX]]] |
| **Sensor** | A process value (temperature, pressure, …) pushed into **Pinetek Insight**. [[pinebox:01_manual|[PBX]]] |
| **Downtime reason** | Category + reason assigned to a Down period, from the catalogue configured in [[insight:manual:07-line-configuration#downtime_reason_catalogue|chapter 7.7]]. |
| **Units in / Units out** | Parts entering the line (input stage) / good parts leaving the line (output stage). |
| **Target quantity** | The planned quantity for a run, entered at changeover. |

A full glossary is provided in [[insight:manual:13-appendicies|Appendix A]].