Reports & Analytics
Turn your production data into clear, useful insights. OpenMES gives you OEE breakdowns, scrap analysis, work order history, cost tracking, non-conformance reports, and MRP planning. Each report answers a real manufacturing question and helps you keep improving.
OEE Report
OEE (Overall Equipment Effectiveness) is the top way to measure how well your factory runs. The OEE Report in OpenMES breaks it down for each line into three parts – Availability, Performance, and Quality. It also shows the combined OEE score: OEE = A × P × Q.
Here are the metrics shown for each line and time period:
| Metric | Formula | What It Measures |
|---|---|---|
| Availability (A) | Run Time / Planned Production Time | Was the line running when it should have been? Losses come from downtime, changeovers, and breakdowns. |
| Performance (P) | Actual Output / Theoretical Maximum Output | Was the line running at full speed? Losses come from slow cycles, minor stops, and reduced speed. |
| Quality (Q) | Good Units / Total Units Produced | How many units passed quality checks? Losses come from scrap, rework, and rejects. |
| OEE | A × P × Q | The overall score. World-class factories aim for 85% or higher. |
You also see Produced Units (total output), Scrap Count (rejects broken down by reason), and Downtime (minutes of unplanned stops). Filter by date, line, product, or shift to dig into the details.
OEE data is calculated automatically. Every time a line starts, stops, makes units, or creates scrap, the system logs it. Break times (set up in HR & Factory Structure) are excluded so they do not lower your Availability score.
Scrap Reports
Scrap Reports use Pareto analysis to show you where waste comes from. They help you find the biggest scrap reasons hurting your Quality score and material costs. The 80/20 rule says that about 80% of scrap usually comes from just 20% of the reasons. This report makes that easy to see.
The Pareto chart shows bars for each scrap reason, sorted from most to least common. A cumulative line shows how much of total scrap each reason explains. Below the chart, a table shows the scrap rate per production line (scrap units / total units). This makes it simple to compare quality across lines.
Scrap data links to the standard Scrap Reasons set up in Products & Traceability. This keeps categories consistent and lets you track trends over weeks, months, and quarters.
Work Order History
Work Order History is your factory's production logbook. It stores all completed work orders in one place. Unlike the active Work Orders screen, this report focuses on past data and how orders actually ran.
For each finished order, you see: Order Number, Product, Planned Quantity vs. Actual Quantity, Planned Start/End vs. Actual Start/End, Execution Time (total hours), On-Time Delivery status (green = on time, red = late), and the Line used.
This helps with capacity planning. You can see how long orders really take versus the estimate. If a product is always late, the planned cycle time or changeover time probably needs fixing. Filter by date, product, line, or on-time status.
Production Cost
The Production Cost report splits each work order's cost into three parts: Material Cost (raw materials used, based on BOM and unit prices), Labor Cost (operator hours times wage rates), and Additional Costs (overheads, tooling, energy, and any extra items you add).
The report shows Total Cost Per Unit by dividing total cost by good units produced. Use it for pricing, margin checks, and spotting orders that cost more than expected. Over time, you can see trends. Are material costs going up? Are some products always more expensive to make than planned?
Non-Conformance Report
The Non-Conformance Report collects all quality issues and deviations into a Pareto chart by type. It goes beyond the Scrap Report (which only covers discarded units). It also includes problems fixed on the line, items sent for rework, and issues escalated for investigation.
Each record links to the work order, the production line, the issue type (from the standard reasons list), any corrective action taken, and the status (open, in progress, closed). The Pareto view shows which issues happen most. The trend view tells you if your fixes are actually working over time.
Net Requirements (MRP)
The Net Requirements report is a simple MRP (Material Requirements Planning) tool. It checks how many components your planned work orders need against what you have in stock and what is on the way (pending purchases or transfers). It flags any shortages you need to fix before production starts.
For each component, you see: Material Name, Total Required Quantity (across all planned orders), Stock On Hand, Expected Receipts, Net Requirement (shortage = required minus on hand minus expected; a positive number means you are short), and the Earliest Need Date (when the first order needs this material).
This is not a full MRP system (that would include lead times, lot sizing, and multi-level BOM explosion). But it gives you the key daily check: "Can we build what we planned?" If you use an external ERP with full MRP, this report works as a handy shop-floor cross-check.