4. 9 Losses-ඵලදායිතාවය අඩුවන අවස්ථා.
1. Start up loss : Time taken to produce the first
product from the time that machine is
activated.
2. Set up & adjustment loss: idling time
erupted to the obtain the required
specification of the relevant product
3. Brake down time: Idling time caused by the
failure of a machine/Machines
5. 9 Losses -ඵලදායිතාවය අඩුවන අවස්ථා.
4. Change over loss: Time loss happened due to
the stopping of production for the change over.
5. Labour/Material shortage: It is the shortage of
out put to the production target, expressed as a
time value.
6. Minor stoppages: It is the sum of total time that
stop the production for less than 5 minutes
7. Cleaning time : It is the time that the production
can’t be planned due to the cleaning
requirement of the process.
6. 9 losses -ඵලදායිතාවය අඩුවන අවස්ථා.
8. Speed loss: It is the shortage of out put
compared to the machine capacity,
expressed as a time value.
9. Defect & rework loss: It is the total amount
of nonconforming out put, expressed as a
time value.
7. 9 Losses-grouped into 3
AVAILABILITY
1. Start up loss
2. Set up & adjustment
loss
3. Change over loss
4. Breakdown loss
5. Cleaning loss
6. Material s & labour
shortage
7. Minor stoppages
PERFORMANCE
8.Speed loss
QUALITY
9. Defect &
rework loss
9. PLANNED TIME
OPERATING TIME IDLE TIME
SPEED
LOSS
NET OPERATING TIME IDLE TIME
SPEED
LOSS
DEFECT &
REWORK
VALUE ADDED OPERATING TIME IDLE TIME
LOSS
10. OEE % = Availability % *Performance %*Quality %
How to calculate OEE
11. How to calculate-Availability
Availability % = (Operating time /planned time)*100
Operating time = Planned time –Idle time
Idle time
Start up loss Labor & material shortage
Set up & adjustment loss Minor stoppages
Change over time Cleaning time
Break down time
12. How to calculate –Performance &
Quality
Performance % =( actual rate/ Rated capacity)*100
Actual rate = Total out put/operating time
Quality % = (Good out put/Total out put)*100
Good out put = Total out put –Defect & rework
13. Example
Planned time = 12hours
Capacity =100kg/hr
Total Out put = 900kg
Defect & rework = 10kg
Brake down =0.5 hours
Start up time = 0.5 hrs
Change over time = .5hrs
Set up adjustment time = 0
Minor stoppages = 0.5hrs
Cleaning time = 0
Material/labour shortage= 0
• Availability% =
• Actual rate =
• Performance %=
• Good out put =
• Quality % =
• OEE=
((12-2)/12)*100= 83.3%
900kg/10hrs=90kg/hr
(90/100)*100=90%
900-10=890kg
(890/900)*100=98.8%
83.3%*90%*98.8%=74.16%
14. Next step
OEE
3 Factors (Availability/Performance/Quality)
9Losses
How to reduce losses
Improve OEE
15. Summary & questions
• What is OEE
• Benefit of OEE
• How to calculate OEE
• 9 losses
• Next step
