oee-pipeline

name	oee-pipeline
description	Generate a production-grade OEE (Overall Equipment Effectiveness) measurement pipeline for a manufacturing line — data ingestion from MQTT/OPC-UA/Modbus/CSV, A×P×Q calculation engine, Six Big Losses categorizer, MTBF/MTTR/TEEP metrics, Grafana or Streamlit dashboard, and downtime alerting. TRIGGER on phrases like "OEE", "overall equipment effectiveness", "downtime tracking", "production monitoring", "Six Big Losses", "manufacturing dashboard", "TEEP", "MTBF", "MTTR", or any user describing a plant floor / line / cell / shift that needs availability × performance × quality measurement. Also trigger when a user says "predictive maintenance" without an OEE foundation in place — OEE must be deployed first per industry best practice (validated 2026 deployment guides). SKIP if the user already has an OEE platform (Tractian, Tulip, MachineMetrics) and just wants to integrate with it — recommend a connector instead.
version	1.0.0
category	analysis
platforms	["CLAUDE_CODE"]

OEE Pipeline Generator

You generate a complete, production-grade Overall Equipment Effectiveness measurement pipeline for a manufacturing line. The output is real code (Python or Node + Grafana/Streamlit), not pseudocode or chat advice.

OEE = Availability × Performance × Quality. World-class is ~85%. Most plants run 40-60%. The gap is almost always invisible because nobody is measuring correctly. Your job is to make it measurable in a few hours of work.

============================================================ === PRE-FLIGHT ===

Before generating any code, gather and verify:

• Data source identified. What is the source of truth for production counts and machine state?
  • MQTT broker (most common in Industry 4.0 deployments — Sparkplug B preferred)
  • OPC UA endpoint (typical for greenfield brownfield with newer PLCs)
  • Modbus TCP/RTU (legacy PLCs — Allen-Bradley, Siemens S7, Mitsubishi)
  • Direct PLC tag read (Rockwell pylogix, Siemens snap7, Beckhoff ADS)
  • CSV / SQL export from existing MES (Ignition, Wonderware, Rockwell FactoryTalk)
  • Manual entry (last resort — generate web form scaffold)
• Cycle time / planned production rate known. OEE Performance = (Total Count × Ideal Cycle Time) / Run Time. Without ideal cycle time, you cannot compute Performance. If unknown, prompt the user or assume the published rate from the OEM datasheet.
• Shift schedule defined. Planned production time vs scheduled downtime (lunch, meetings, planned PM) must be distinguishable.
• Reject/scrap counting available. Quality = Good Count / Total Count. If only Total is available, generate a stub that flags this as a known limitation.
• Output language chosen. Default Python (best ecosystem for industrial data — pandas, numpy_financial, pymodbus, asyncua, paho-mqtt). Use Node if the user has a Node-first stack.

Recovery if anything is missing:

• Generate a stub data source adapter with mock data so the rest of the pipeline can be tested in isolation.
• Mark the stub clearly: # TODO: replace with real <protocol> connection — see references/connectors.md.
• Do NOT halt the entire skill — output a working scaffold with a known gap, not nothing.

============================================================ === PHASE 1: SCAFFOLD THE PROJECT ===

Generate this layout in the current working directory (or a subfolder if the user specifies one):

oee/
├── README.md                    # Quickstart, formulas, deployment notes
├── pyproject.toml               # or package.json if Node
├── docker-compose.yml           # Local stack: broker + Grafana + InfluxDB
├── src/
│   ├── ingest/
│   │   ├── mqtt_source.py       # paho-mqtt + Sparkplug B decoder
│   │   ├── opcua_source.py      # asyncua subscription
│   │   ├── modbus_source.py     # pymodbus TCP/RTU
│   │   └── mock_source.py       # for testing without hardware
│   ├── oee/
│   │   ├── calc.py              # core A×P×Q formulas
│   │   ├── six_big_losses.py    # downtime categorizer
│   │   └── metrics.py           # MTBF, MTTR, TEEP, NEE
│   ├── storage/
│   │   └── influx_writer.py     # InfluxDB or TimescaleDB writer
│   └── dashboard/
│       └── grafana_dashboard.json
└── tests/
    └── test_oee_calc.py         # validates formulas against published examples

VALIDATION: Every directory exists. Every file has at least a docstring and one runnable function. Tests pass against the published OEE example: A=0.80, P=0.85, Q=0.95 → OEE=0.6460.

FALLBACK: If the user's existing project structure is incompatible (Django app, Flask, etc.), embed the OEE module as a single package without forcing the folder layout.

============================================================ === PHASE 2: OEE CALCULATION ENGINE ===

Generate src/oee/calc.py with the exact formulas:

# Availability = Run Time / Planned Production Time
# Planned Production Time = Shift Length - Planned Stops
# Run Time = Planned Production Time - Unplanned Stops

# Performance = (Ideal Cycle Time × Total Count) / Run Time
# Equivalent: Performance = (Total Count / Run Time) / Ideal Run Rate

# Quality = Good Count / Total Count

# OEE = Availability × Performance × Quality
# TEEP = OEE × Utilization (Utilization = Planned Production Time / All Time)
# NEE  = Availability_uptime × Performance × Quality (excludes planned downtime)

Edge cases the engine MUST handle:

• Microstops (< 5 min) → classified as Performance loss, NOT Availability loss (industry convention).
• Speed loss → Performance < 1.0 even with no stops; surface as separate metric.
• Startup/changeover rejects → categorized separately in Quality (Six Big Losses #5).
• Performance > 100% → clamp to 1.0 AND emit warning (ideal cycle time may be set too conservatively).
• Zero planned production time → return None, do NOT divide-by-zero.

Cite the formulas inline using a reference comment so future maintainers can audit:

# Source: ISO 22400-2:2014 Key Performance Indicators for Manufacturing Operations Management

VALIDATION: Unit tests in tests/test_oee_calc.py cover: known-good values, divide-by-zero, P>1.0 clamp, partial shift, all-scrap output. All tests must pass.

FALLBACK: If a formula edge case is ambiguous (e.g., how to handle a machine running during a planned stop), default to the ISO 22400-2 interpretation and add a TODO comment explaining the assumption.

============================================================ === PHASE 3: SIX BIG LOSSES CATEGORIZER ===

Generate src/oee/six_big_losses.py that classifies downtime events into the canonical six categories:

#	Loss Category	OEE Bucket	Detection Rule (default)
1	Breakdowns / Equipment failure	Availability	unplanned stop > 5 min, fault code present
2	Setup & Adjustments	Availability	stop tagged "changeover" or between product runs
3	Small Stops / Idling	Performance	stop 0–5 min, no operator intervention
4	Reduced Speed	Performance	running but actual_rate < ideal_rate
5	Startup Rejects	Quality	scrap within first N units after run start
6	Production Rejects	Quality	scrap during steady-state production

The categorizer takes a stream of state events (timestamp, state, duration, fault_code, product) and emits classified loss events. Output schema must be JSON-serializable so it flows into the dashboard without ETL.

VALIDATION: Run the categorizer against a synthetic 8-hour shift in tests; verify that the six categories sum to the total loss within rounding.

FALLBACK: If fault codes are not available, classify all unplanned stops > 5 min as Breakdowns and emit a "fault_code_missing" warning so the user knows the granularity gap.

============================================================ === PHASE 4: DATA INGESTION ADAPTER ===

Generate the ingestion adapter matching the user's data source. Each adapter MUST:

1. Externalize credentials via environment variables — never hardcode.
2. Use TLS / mutual auth where the protocol supports it (Sparkplug B + TLS, OPC UA with X.509).
3. Handle reconnect with exponential backoff (start 1s, cap 60s).
4. Emit a canonical event schema regardless of source protocol:

   {
     "ts": "ISO8601",
     "asset_id": "line-1",
     "metric": "good_count",
     "value": 1247,
     "quality": "GOOD"
   }
   

MQTT Sparkplug B specifics:

• Subscribe to spBv1.0/{group}/DDATA/{edge_node}/{device}.
• Decode protobuf payload (sparkplug_b.proto — include a copy in vendor/).
• Handle NBIRTH/DBIRTH to learn the metric schema before processing DDATA.

OPC UA specifics:

• Use asyncua (Python) — modern, asyncio-native, maintained.
• Subscribe to changes (not poll). Set publishing interval to match the desired sample rate.
• Browse the address space at startup, persist the discovered NodeIds to config/opcua_nodes.yaml.

Modbus specifics:

• Use pymodbus. Register maps live in config/modbus_map.yaml.
• Convert raw 16-bit registers to engineering units via the configured scale/offset.

VALIDATION: Adapter connects to a local broker (run via docker-compose) and emits at least 10 sample events in python -m src.ingest.<adapter> --test mode.

FALLBACK: If the protocol-specific library is unavailable in the user's environment, generate mock_source.py that replays a recorded CSV — pipeline still demonstrable end-to-end.

============================================================ === PHASE 5: DASHBOARD ===

Generate src/dashboard/grafana_dashboard.json (preferred) OR a Streamlit app at src/dashboard/app.py.

The dashboard MUST include:

1. Big-number OEE for the current shift (large, color-coded: red < 60%, yellow 60-85%, green > 85%).
2. A / P / Q breakdown (three stacked single-stats — shows WHERE the loss is).
3. Six Big Losses Pareto chart (descending bar — shows WHY).
4. Hourly OEE trend (last 24h line chart).
5. Top 10 downtime events (table — duration, reason, asset).
6. MTBF / MTTR / TEEP trio (secondary metrics).

Grafana panel queries must use the canonical event schema from Phase 4 so the dashboard works without per-deployment query editing.

VALIDATION: Import the JSON into a fresh Grafana instance (Grafana ≥ 10) and confirm all 6 panels render without errors against the mock data source.

FALLBACK: If Grafana setup is too heavy for the user, generate Streamlit (single streamlit run app.py).

============================================================ === PHASE 6: README & DEPLOYMENT NOTES ===

Write README.md with:

• One-paragraph summary of what the pipeline does.
• Quickstart: docker-compose up && python -m src.ingest.mock_source && open http://localhost:3000.
• Formula reference table (so non-engineers can audit calculations).
• How to swap the mock source for the real PLC/MQTT/OPC-UA source.
• Industry context: "Deploy OEE first as foundation. Layer predictive maintenance as a 12-24 month follow-on. ROI for OEE alone is typically 9-18 months." [cite: 2026 TeepTrak deployment guide]
• Known limitations (if any from PRE-FLIGHT gaps).

VALIDATION: README quickstart actually works on a fresh machine.

============================================================ === SELF-REVIEW ===

Score each dimension 1–5:

• Complete: Does the pipeline ingest real or simulated data, compute OEE correctly per ISO 22400-2, categorize the Six Big Losses, and render a usable dashboard?
• Robust: Does the calc handle microstops, divide-by-zero, P>1.0 clamp, partial shifts? Does the ingestion reconnect on failure?
• Clean: Is the code formatted (black/ruff for Python), typed (mypy/pyright clean), and free of unused stubs?
• Industry-credible: Would a controls engineer / continuous improvement engineer recognize the terminology and formulas as correct? (This is the killer dimension — wrong formulas destroy trust instantly.)

If any < 4:

• Identify the specific gap. Most common gap: Performance formula uses average cycle time instead of ideal cycle time → silently inflates OEE. Fix and re-test.
• If a gap is genuinely unfixable in this run (e.g., the user can't provide ideal cycle time), note it in the README under "Known Limitations" with a clear remediation path.

============================================================ === LEARNINGS CAPTURE ===

After completing, append to ~/.claude/skills/oee-pipeline/LEARNINGS.md:

— <site/line/protocol context, e.g., "CNC mill, Sparkplug B">

• What worked: <specific approach — formula reference, dashboard layout, adapter pattern>
• What was awkward: <step that needed retry — e.g., "user couldn't provide ideal cycle time, defaulted to OEM spec">
• Suggested patch: <concrete improvement — e.g., "add pre-flight question for whether MES data already exists">
• Verdict: [Smooth / Minor friction / Major friction]

============================================================ === STRICT RULES ===

• Never invent formula variants. Use ISO 22400-2 conventions or cite an explicit alternative.
• Never hardcode credentials or broker URLs. Externalize via env vars.
• Never claim a number you didn't calculate from real or mock data. The dashboard MUST be backed by the calc engine, not by static placeholders.
• Never skip the Six Big Losses categorizer. Total OEE without the loss breakdown is the most common failure mode — it tells management things are bad without telling engineers what to fix.
• If the user has an existing OEE platform, do NOT regenerate the pipeline — recommend a connector instead.