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Measure Manufacturing Performance with OEE and TEEP
- 2. Manufacturing Performance-OEE Overall Equipment Effectiveness(OEE) helps manufacturers to measure manufacturing productivity . OEE measurement gives insight for underlying losses . It measures the percentage of scheduled productive time that is fully productive. OEE= Availability X Performance X Quality where , Availability = Run Time/Planned Production Time Performance =(Ideal Cycle Time X Total Count)/Run Time Quality= Good Count / Total Count hence ; OEE= Good Count X Ideal Cycle Time)/Planned Production Time
- 3. Manufacturing Performance-TEEP Total Overall Equipment Effectiveness (TEEP) helps the manufacturers to analyze and improve asset utilization and hence provide the true potential of a manufacturing operation . It is a method of performance measurement with respect to total capacity. It measures the percentage of total calendar hours that are fully productive. TEEP= Availability X Performance X Quality X Utilization where , Utilization = Planned Production Time/All Time
- 4. EFFECTIVENESS LOSSES -Process defects -Reduced Yields NOT SCHEDULED TIME (No shift planned for production ) OVERALL EQUIPMENT EFFECTIVENESS TOTAL EFFECTIVE EQUIPMENT PERFORMANCE QUALITY PERFORMANCE AVAILABILITY All Available Time(24 hrs -365 days a year) Quality Losses Performance Losses -Minor Stoppages/Idling -Reduced Speed Availability Losses -Equipment breakdown -Setup & Adjustments GOOD PRODUCT ACTUAL OUTPUT ACTUAL OUTPUT THEORETICAL PUTPUT= Running Time X Theoretical Speed) ACTUAL PRODUCTION TIME(Machine running) POTENTIAL PRODUCTION TIME(Actual 'Shift Time') OEE & TEEP
- 5. OEE & TEEP OEE- Overall Equipment Effectiveness TEEP- Total Effective Equipment Performance What Effectiveness of equipment Effectiveness of Management in extracting value from assets Measurement Measurement of Operating effectiveness. Measurement of revenue effectiveness Decision making Tool Tool for Decision making- Improvement scope Tool for Decision making- Capital Investment How to Calculate OEE= Availability X Performance X Quality TEEP=OEE X Utilization Downtime-Avaliability Losses Shutdown Losses Speed-Performance Losses Quality-Acceptance Losses Factors Eg.:No Demand,Time not scheduled
- 6. OEE - Six Big Losses UNPLANNED STOPS Equipment Breakdowns PLANNED STOPS Setup and Adjustments SMALL STOPS IdIng and Minor Stops SLOW CYCLES Reduced Speeds PRODUCTION REJECTS Process Defects STARTUP REJECTS Reduced Yields OEE FULLY PRODUCTIVE TIME Valuable Operating Time Overall Equipment Effectiveness SIX BIG LOSSES AVAILABILITY LOSS PERFORMANCE LOSS QUALITY LOSS
- 7. Countermeasures for SIX losses S.No. SIX Loss Category OEE Measure Reasons for Losses Countermeasures Changeover SMED Asset Care Benchmrking Planned Maintenance Planned Downtime log /Matrix Material Shortages ABC Planning Labour Shortages Equipment Failure Asset Care or Preventive Maintenance Major Component failure CLIT Unplanned Maintenance Root Cause Analysis Short Equipment Failure Reduction of MTBF Fallen product Periodic Servicing by Manufacturer (AMC) Obsurtuction Focussed Improvement Blockages SIC Running lower than rated speed Optimization-Line Balancing Untrained Operator not able to Training and awareness of line balancing run at nominal speed Machine Iding Product out of spection Root Cause Analysis Damaged product SPC Scrap Product out of spection at machine start Precision settings Damaged product SOP-Complete all checks before startup Scrap 4 Speed Loss PERFORMANCE QUALITY Production Rejects 5 6 Startup Rejects QUALITY Planned Downtime /External unplanned event AVAILABILITY 1 AVAILABILITY Breakdowns 2 PERFORMANCE Minor Stops 3
- 8. REFERENCES • https://academy.lineview.com. • Jayaswal, Rajput :"A Total Productive Maintenance Approach to Improve Overall Equipment Effectiveness." International Journal of Modern Engineering Research, 2012: 4383-4386.