Overall Equipment Effectiveness

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Overall Equipment Effectiveness

  1. 1. WELCOME
  2. 2. KAILAS SREE CHANDRAN CLASS: S7 INDUSTRIAL 432 Guide: V REGIKUMAR OVERALL EQUIPMENT EFFECTIVENESS OEE
  3. 3. MODERN APPROACH TO OVERALL EQUIPMENT EFFECTIVENESS OEE
  4. 4. 2
  5. 5. 3
  6. 6. 4
  7. 7. 5
  8. 8.  Loss due to breakdown of equipment.  Loss is more than 10 minutes. 6  Biggest of SIX BIG LOSSES.  Tooling Failures  Unplanned Maintenance  General Breakdowns  Equipment Failure
  9. 9.  The time lost due to adjustments in the equipment. 7  Loss is less then 10 minutes.  Setup/ Changeover  Material Shortages  Major Adjustments
  10. 10.  Small stops losses occur when equipment stops for a short time as a result of a temporary problem. 8  These includes stops that are under ten minutes.  Component Jams  Misfeeds  Sensor Blocked  Delivery Blocked  Cleaning/ Checking
  11. 11.  Reduced speed refers to the difference between Design speed and Actual Operating speed. 9  Under Nameplate Capacity  Under Design Capacity  Due to Equipment Wear  Due to Operator Inefficiency
  12. 12.  Some equipments require warm- up time and certain adjustments 10 to obtain optimum output. Startup rejection occurs during this startup time.  Scrap  Rework
  13. 13.  These losses occurs when products produced are not conforming to the specifications. 11  These are rejects during steady-state production.  Scrap  Rework
  14. 14. 12
  15. 15.  The amount of time the facility is open and available for operation. 13  One year consists of 365 days, one day consists of 24 hours, 60 minutes in one hour, 60 seconds in one minute.  PLANT OPERATING TIME = Fully Productive Time + Quality Loss + Speed Loss + Downtime Loss + Planned Shutdown
  16. 16. PLANT OPERATING TIME 14 PLANNED PLANNED PRODUCTION TIME SHUTDOWN DOWNTIME OPERATING TIME LOSS SPEED NET OPERATING TIME LOSS QUALITY FULLY PRODUCTIVE TIME LOSS
  17. 17. OEE FACTORS 15
  18. 18.  Availability represents the percentage of scheduled time that the equipment is 16 available to operate.  Availability takes into account Down Time Losses. AVAILABILITY = Operating Time Planned Production Time
  19. 19.  Performance represents the speed at which the equipment runs as a 17 percentage of its designed speed.  Performance takes into account Speed loss. PERFORMANCE = Net Operating Time Operating Time
  20. 20.  Quality represents the Good units produced as a percentage of the Total 18 units produced. QUALITY = Fully Productive Time Net Operating Time
  21. 21. PERFORMANCE AVAILABILITY= =Actual Run Operating time/ Rate/ Ideal Run Planned Rate Production Time 19 QUALITY= Good Pieces/ Total Pieces
  22. 22. 20
  23. 23. 21
  24. 24. 22
  25. 25. OEE= AVAILABILITY X PERFORMANCE X QUALITY 23 Availability = Operating Time / Planned Production Time Performance = (Total Pieces / Operating Time) / Ideal Run Rate Quality = Good Pieces / Total Pieces
  26. 26.  This method use computers for accessing inputs, calculating OEE 24 and its analysis.  E.g.: OEE IMPACT, VISUAL OEE, OEE TOOLKIT, PROVIDEAM etc.  Spreadsheets  System Software
  27. 27. o Shift Length: 8 Hours o Tea Breaks: 10 Minutes x 2 25 o Meals Break: 1 Hour o Downtime: 10% of shift o Idle Runrate: 5 pieces/minute (Cycle time=0.2min/pieces) o Total Pieces Produced: 1600 o Rejected Pieces: 52
  28. 28. OEE= Availability x Performance x Quality Availability = Operating Time/ Planned 26 Production Time Planned Production Time = Plant Operating Time – Planned Shutdown Plant Operating Time= 8 hours x 60 = 480 min. Planned Shut down = Tea break + Lunch Break = (10x2) + 60 = 80minutes.
  29. 29. Planned Production Time = 480-80 = 400 min. Operating Time = Planned Production Time- Downtime Loss = 400-48 = 352 minutes. Availability = 352/400 = 0.88 Performance = (Total Pieces / Operating Time)/ 27 Idle Run Rate = (1600/352) / 5 = 0.9091 Quality = Good Pieces / Total Pieces = (1600-52) / 1600 = 0.9675 OEE = 0.88 x 0.9091 x 0.9675 = 0.774 OVERALL EQUIPMENT EFFECTIVENESS = 77.4%
  30. 30. OVERALL EQUIPMENT EFFECTIVENESS (EXCEL CALCULATOR) Production Data Shift Length 8 Hours = 480 Minutes Short Breaks 2 Breaks @ 10 Minutes Each = 20 Minutes Total Meal Break 1 Breaks @ 60 Minutes Each = 60 Minutes Total Down Time 48 Minutes Ideal Run Rate 5 PPM (Pieces Per Minute) Total Pieces 1,600 Pieces Reject Pieces 52 Pieces Support Variable Calculation Result Planned Production Time Shift Length - Breaks 400 Minutes Operating Time Planned Production Time - Down Time 352 Minutes Good Pieces Total Pieces - Reject Pieces 1,548 Pieces 28 OEE Factor Calculation OEE% Availability Operating Time / Planned Production Time 88.00% Performance (Total Pieces / Operation Time) / Ideal Run Rate 90.91% Quality Good Pieces / Total Pieces 96.75% Overall OEE Availability x Performance x Quality 77.40% World OEE Factor OEE% Class OEE Availability 90.00% 88.00% Performance 95.00% 90.91% Quality 99.90% 96.75% Overall OEE 85.00% 77.40%
  31. 31.  World class OEE is a standard which is used to compare the OEE of the firm. 29 OEE Factor WORLD CLASS Availability 90% Performance 95% Quality 99% Overall Equipment 85% Effectiveness
  32. 32. 30
  33. 33. PLANT OPERATING TIME PLANNED PLANNED PRODUCTION TIME SHUTDOWN 31 DOWNTIME OPERATING TIME LOSS STOPTIME RUNNING TIME LOSS SPEED NET OPERATING TIME LOSS FULLY PRODUCTIVE QUALITY TIME LOSS
  34. 34.  Usability takes into account Stop Time Loss. 32 USABILITY = Running Time Operating Time
  35. 35. OEE 33 Availability Usability Performance Quality
  36. 36. 34
  37. 37. o Shift Length: 8 Hours Downtime Loss of 48 o Tea Breaks: 10 Minutes x 2 minutes (10% of Shift) o Meals Break: 1 Hour 35 o Warm-up Time: 20 minutes o Equipment Breakdown(Tool Failure): 28 min. o Idle Runrate: 5 pieces/minute (Cycle time=0.2min/pieces) o Total Pieces Produced: 1600 o Rejected Pieces: 52
  38. 38. Availability = Operating Time/ Planned Production Time Planned Production Time = 400 minutes Operating Time = Planned Production Time- Breakdowns = 400-28 = 372 minutes. 36 Availability = 372/400 = 0.93 Usability = Running time / Operating Time Running Time = Operating Time – Warm-up Time = 372-20 = 352 minutes. Usability = 352 / 372 = 0.9462
  39. 39. Performance =(Total Pieces / Operating Time) / Idle Run Rate = (1600 / 352) / 5 = 0.9091 Quality = Good Pieces / Total Pieces = (1600-52) / 1600 = 0.9675 OEE = Availability x Usability x Performance x 37 Quality OEE = 0.93 x 0.9462 x 0.9091 x 0.9675 = 0.774 Modified OVERALL EQUIPMENT EFFECTIVENESS = 77.4%
  40. 40. 38
  41. 41. 39
  42. 42.  Anil S. Badiger, ‘A proposal: evaluation of OEE and impact of six big losses’, Int. J. Process Management and Benchmarking, 40 Vol.2, No. 3, 2008, pp 234-248.  Ravikumar M. M., ‘Improving Equipment Effectiveness’, Int. Business Management, Vol. 3, No.2, 2008, pp 91-96.  www.bestmanagementarticles.com  www.maintenanceworld.com

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