The document discusses overall equipment effectiveness (OEE) and its calculation. It defines OEE as the product of availability, performance, and quality. Availability accounts for downtime losses. Performance considers speed losses. Quality looks at good units produced. The document provides an example calculation of OEE for a machine with a 77.4% effectiveness rate. It also modifies the OEE calculation to include usability which accounts for stop time losses.

1. WELCOME

2. KAILAS SREE CHANDRAN
CLASS: S7 INDUSTRIAL 432
Guide: V REGIKUMAR
OVERALL EQUIPMENT EFFECTIVENESS
OEE

3. MODERN APPROACH TO
OVERALL EQUIPMENT EFFECTIVENESS
OEE

4. 2

5. 3

6. 4

7. 5

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.  The time lost due to adjustments
in the equipment.
7  Loss is less then 10 minutes.
 Setup/ Changeover
 Material Shortages
 Major Adjustments

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.  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.  Some equipments require warm-
up time and certain adjustments
10
to obtain optimum output.
Startup rejection occurs during
this startup time.
 Scrap
 Rework

13.  These losses occurs when products
produced are not conforming to the
specifications.
11
 These are rejects during steady-state
production.
 Scrap
 Rework

14. 12

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. PLANT OPERATING TIME
14 PLANNED
PLANNED PRODUCTION TIME SHUTDOWN
DOWNTIME
OPERATING TIME LOSS
SPEED
NET OPERATING TIME LOSS
QUALITY
FULLY PRODUCTIVE TIME
LOSS

17. OEE FACTORS
15

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.  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.  Quality represents the Good units
produced as a percentage of the Total
18 units produced.
QUALITY = Fully Productive Time
Net Operating Time

21. PERFORMANCE AVAILABILITY=
=Actual Run Operating time/
Rate/ Ideal Run Planned
Rate Production Time
19 QUALITY=
Good Pieces/
Total Pieces

22. 20

23. 21

24. 22

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.  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. 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. 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. 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. 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.  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. 30

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.  Usability takes into account Stop Time
Loss.
32
USABILITY = Running Time
Operating Time

35. OEE
33
Availability Usability Performance Quality

36. 34

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. 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. 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. 38

41. 39

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