Overall Equipment

1. Overall Equipment Effectiveness (OEE)
1
OVERALL EQUIPMENT EFFECTIVENESS (OEE)
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Logix Automation Systems Pvt. Ltd.

2. Overall Equipment Effectiveness (OEE)
2www.logixind.comwww.factorypulse.in
OEE
Elements of
OEE
OEE is the way to
Measure Effectiveness
Prime Cause of
Production Loss OEE Calculation
How to increase
OEE ?
Fundamental Concept
of plant Effectiveness
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Logix Automation Systems Pvt. Ltd.

3. Overall Equipment Effectiveness (OEE)
3
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Overall equipment effectiveness (OEE) is a hierarchy of metrics to
evaluate how effectively a manufacturing operation is utilized.
In an ideal factory, equipment would operate 100 percent of the time
at 100 percent capacity, with an output of 100 percent good quality.
The difference between the ideal and the actual situation is due to
losses. Calculating the overall equipment effectiveness (OEE) rate is a
crucial element of any serious commitment to reduce equipment- and
process-related wastes.

4. Elements Of OEE
4
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Overall
Equipment
Effectiveness
Availability
losses
Performance
losses
Quality
losses
Set-up
Breakdown
Minor
Stoppages
Speed
losses
Start-up
losses
In process
losses
Inconsistent Timings, Insufficient Skills, Poor Planning & Scheduling, Different
methods, Poor Tooling, Poor start up controls, Missing Parts, Insufficient support,
Excessive start-up adjustments
Lack of Maintenance, Low Operator Interest, Not knowing of problems,
Poor Training, Design Problems, Inferior Material
Material not Available, Change Over at Start/End, Jams/Misfeeds/
Overloads, Operator Error, Operator Absence
Unclear Design Specs, Poor Maintenance History, Incorrect Settings, Poor
Training, Speed Deliberately Reduced, Inconsistent Material
Poor Product Changeover, Inconsistent Materials, No start-up check lists, Waiting
for Temp, Pressure, Minor adjustments
Environmental Conditions, Inconsistent Material, Process not followed, Poor
Calibration, Gauges not calibrated properly etc.

5. OEE is the way to Measure Effectiveness
5
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OEE is the way to measure how effectively Machine/Equipment hours are used
Total time
e.g. 480 min. (1 shift (8 hrs))
Available time
Running time
Productive time
Effective time
Planned
Downtime
Downtime
Performance
Losses
Quality Losses
OEE goes down due to following Losses
- breakdowns, repairs
- changeover
- adjustment
- start up
- machine speed
- short stoppages
- lower yield
- scrap
- reject
- rework
- breaks, planned
maintenance, training

6. Prime Cause of Production Loss
6
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Logix Automation Systems Pvt. Ltd.
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A production line seldom operates at optimum speed. A myriad of reasons or Negative
Performance Impacts, mostly in combination, cause losses in productivity and therefore loss
of money. These include:
•Line Saturation
There is no place for more output from the machine. For example, a filling machine of a bottling
line is running at its max. speed.
•Equipment Failure
Machines break down, wear out, are not used properly and so on. All ends up in lost production
time.
•Product changes
During the change over from one product to another the machine settings must be changed,
breakdown may occur and speed must be reduced.
•Short Stops
For example, a bottle falls down in a bottling machine and the operator picks it up. These short but
frequent events can be the reason for major time loss.
•Operator Inefficiency
The operators like to have it nice and easy. They run with lower speed in order to guarantee smooth
operation.

7. Prime Cause of Production Loss
7
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•External reasons
Sometimes, the production runs out of orders and the machines have to shut down. Or there can
be a failure in the electrical power network far away from the factory.
•Product Type
Some products are more difficult to make. There are more breakdowns and quality problems.
•Speed Losses
For one reason or another, the speed of the machine is not optimum. In order to save costs,
someone has purchased cheap but poor quality raw material.
•Quality
Although the machine is running, the products are not good enough for the customers. These are
the most expensive kinds of losses.
•Missing Material
The raw material storage is empty and machines can not produce any more.

8. Overall Equipment Effectiveness Calculation
8
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Logix Automation Systems Pvt. Ltd.
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=
340 min – 70 min
340 min
Quality =
Productive time - Quality loss time
Productive time
= 270 min - 20 min
270 min
Running Efficiency =
Available time - Downtime
Availability
420 min - 80 min
420 min
factor 81%
factor 79.4%
factor 92.6%
X
X
= 59.6%
OEE (in %) =
Overall Equipment Effectiveness
Productive Performance=
Running time - Performance loss
Running time

9. How to Improve OEE ?
9
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Logix Automation Systems Pvt. Ltd.
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Data collection is the most important action to increase OEE
Collect data for all downtimes
and losses on the machine
Data Analytics with
graphs and charts
Make improvements visible
J F M A M J J A S O N D
OEE Trend
Target 2003
Analysis
5
10
15
20
25
30
35
Repair Changeover Tool change Scrap Minor Stopp.
33 26 16 7 3
Repairs
Change over
Tool change
Minor stoppages
Autonomous Maintenance
Preventive Maintenance
Changeover Reduction
Standardize Tooling
Improved Machine
Reliability
Standardisation
wastege
Adjustments
rework

10. Fundamental Concept of Plant Effectiveness
10
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Machine Failure
Set up & adjustments
Start-up losses
Minor stoppages
Speed Losses
Defects and Rework
Shutdown
Management losses
Motion
Line organization
Logistics
Adjustments
8 availability losses
Loss of energy
Yield losses
16 Kinds of loss
5 productivity losses
Tool changes
Die, Jig and tool losses
3 production/ cost losses
– not part of OEE -

11. OEE (Overall Equipment Effectiveness)
11
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Logix Automation Systems Pvt. Ltd.
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Thank You
For more information
Logix Automation Systems Pvt. Ltd.
Ph. +91-98140-35599; +91-92167-36975
Email :info@factorypulse.in
Website :www.factorypulse.in