Overall Equipment Effectiveness

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KAILAS SREE CHANDRAN CLASS: S7 INDUSTRIAL 432 Guide: V REGIKUMAR

OVERALL EQUIPMENT EFFECTIVENESS

OEE

MODERN APPROACH TO

OVERALL EQUIPMENT EFFECTIVENESS

OEE

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 Loss due to breakdown of equipment.  Loss is more than 10 minutes.  Biggest of SIX BIG LOSSES.  Tooling Failures  Unplanned Maintenance  General Breakdowns

 Equipment Failure

 The time lost due to adjustments 7

in the equipment.  Loss is less then 10 minutes.  Setup/ Changeover

 Material Shortages  Major Adjustments

 Small stops losses occur when equipment

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stops for a short time as a result of a temporary problem.  These includes stops that are under ten minutes.  Component Jams  Misfeeds

 Sensor Blocked  Delivery Blocked  Cleaning/ Checking

 Reduced speed refers to the 9

difference between Design speed and Actual Operating speed.  Under Nameplate Capacity  Under Design Capacity  Due to Equipment Wear  Due to Operator Inefficiency

 Some equipments require warm10

up time and certain adjustments to obtain optimum output. Startup rejection occurs during this startup time.  Scrap  Rework

 These losses occurs when products

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produced are not conforming to the specifications.  These are rejects during steady-state production.  Scrap  Rework

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 The amount of time the facility is open and 13

available for operation.  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

PLANT OPERATING TIME 14

PLANNED SHUTDOWN

PLANNED PRODUCTION TIME DOWNTIME LOSS

OPERATING TIME NET OPERATING TIME FULLY PRODUCTIVE TIME

QUALITY LOSS

SPEED LOSS

OEE FACTORS 15

 Availability represents the percentage 16

of scheduled time that the equipment is available to operate.  Availability takes into account Down Time Losses. AVAILABILITY =

Operating Time Planned Production Time

 Performance represents the speed at 17

which the equipment runs as a percentage of its designed speed.  Performance takes into account Speed loss. PERFORMANCE = Net Operating Time Operating Time

 Quality represents the Good units 18

produced as a percentage of the Total units produced. QUALITY = Fully Productive Time Net Operating Time

PERFORMANCE =Actual Run Rate/ Ideal Run Rate

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AVAILABILITY= Operating time/ Planned Production Time

QUALITY= Good Pieces/ Total Pieces

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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

 This method use computers for 24

accessing inputs, calculating OEE and its analysis.  E.g.: OEE IMPACT, VISUAL OEE, OEE TOOLKIT, PROVIDEAM etc.  Spreadsheets  System Software

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o Shift Length: 8 Hours o Tea Breaks: 10 Minutes x 2 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

OEE= Availability x Performance x Quality 26

Availability = Operating Time/ Planned 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.

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Planned Production Time = 480-80 = 400 min. Operating Time = Planned Production TimeDowntime Loss = 400-48 = 352 minutes. Availability = 352/400 = 0.88 Performance = (Total Pieces / Operating Time)/ 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%

OVERALL EQUIPMENT EFFECTIVENESS (EXCEL CALCULATOR) Production Data Shift Length Short Breaks Meal Break Down Time Ideal Run Rate Total Pieces Reject Pieces

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8 2 1 48 5 1,600 52

Hours = 480 Minutes Breaks @ 10 Minutes Each = Breaks @ 60 Minutes Each = Minutes PPM (Pieces Per Minute) Pieces Pieces

Support Variable Planned Production Time Operating Time Good Pieces

Calculation

OEE Factor Availability Performance Quality

Calculation Operating Time / Planned Production Time (Total Pieces / Operation Time) / Ideal Run Rate Good Pieces / Total Pieces

Overall OEE

Availability x Performance x Quality

OEE Factor

World Class OEE

Availability Performance Quality Overall OEE

Result

Shift Length - Breaks Planned Production Time - Down Time Total Pieces - Reject Pieces

90.00% 95.00% 99.90%

20 Minutes Total 60 Minutes Total

OEE% 88.00% 90.91% 96.75%

85.00% 77.40%

400 Minutes 352 Minutes 1,548 Pieces

OEE% 88.00% 90.91% 96.75%

77.40%

 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 Effectiveness

85%

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PLANT OPERATING TIME PLANNED SHUTDOWN

PLANNED PRODUCTION TIME 31 DOWNTIME LOSS

OPERATING TIME STOPTIME LOSS

RUNNING TIME NET OPERATING TIME FULLY PRODUCTIVE TIME

QUALITY LOSS

SPEED LOSS

 Usability takes into account Stop Time 32

Loss.

USABILITY = Running Time Operating Time

OEE 33

Availability

Usability

Performance

Quality

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o Shift Length: 8 Hours

o Tea Breaks: 10 Minutes x 2 o Meals Break: 1 Hour 35

Downtime Loss of 48 minutes (10% of Shift)

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

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Availability = Operating Time/ Planned Production Time Planned Production Time = 400 minutes Operating Time = Planned Production TimeBreakdowns = 400-28 = 372 minutes. 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

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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 Quality

OEE = 0.93 x 0.9462 x 0.9091 x 0.9675 = 0.774

Modified OVERALL EQUIPMENT EFFECTIVENESS = 77.4%

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 Anil S. Badiger, ‘A proposal: evaluation of

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OEE and impact of six big losses’, Int. J. Process Management and Benchmarking, 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