Overall Equipment Effectiveness (OEE)
OVERALL EQUIPMENT EFFECTIVENESS (OEE)
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Overall Equipment Effectiveness (OEE)
OEE
Prime Cause of
Production Loss
Elements of
OEE
OEE Calculation
OEE is the way to
Measure Effectiveness
How to increase
OEE ?
Fundamental Concept
of plant Effectiveness
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Logix Automation Systems Pvt. Ltd.
Overall Equipment Effectiveness (OEE)
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.
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Elements Of OEE
Set-up
Inconsistent Timings, Insufficient Skills, Poor Planning & Scheduling, Different
methods, Poor Tooling, Poor start up controls, Missing Parts, Insufficient support,
Excessive start-up adjustments
Availability
losses
Overall
Equipment
Effectiveness
Performance
losses
Breakdown
Lack of Maintenance, Low Operator Interest, Not knowing of problems,
Poor Training, Design Problems, Inferior Material
Minor
Stoppages
Material not Available, Change Over at Start/End, Jams/Misfeeds/
Overloads, Operator Error, Operator Absence
Speed
losses
Start-up
losses
Quality
losses
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In process
losses
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.
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OEE is the way to Measure Effectiveness
OEE is the way to measure how effectively Machine/Equipment hours are used
Total time
e.g. 480 min. (1 shift (8 hrs))
OEE goes down due to following Losses
Available time
Planned
Downtime
- breaks, planned
maintenance, training
Running time
Downtime
- breakdowns, repairs
- changeover
- adjustment
- start up
Productive time
Performance
Losses
- machine speed
- short stoppages
- lower yield
Quality Losses
- scrap
- reject
- rework
Effective time
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Prime Cause of Production Loss
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.
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Prime Cause of Production Loss
•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.
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Overall Equipment Effectiveness Calculation
Running Efficiency =
Available time - Downtime
Availability
420 min - 80 min
420 min
Productive Performance=
=
Quality =
=
Running time - Performance loss
factor 81%
X
Running time
340 min – 70 min
340 min
Productive time - Quality loss time
factor 79.4%
X
Productive time
270 min - 20 min
270 min
Overall Equipment Effectiveness
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OEE (in %) =
factor 92.6%
= 59.6%
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How to Improve OEE ?
Data collection is the most important action to increase OEE
Collect data for all downtimes
and losses on the machine
Repairs
Change over
Data Analytics with
graphs and charts
Make improvements visible
Analysis
35
30
25
20
15
10
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Autonomous Maintenance
Preventive Maintenance
Tool change
Changeover Reduction
Repair
Minor stoppages
33
wastege
Changeover Tool change
26
16
Scrap
Minor Stopp.
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3
OEE Trend
Adjustments
Target 2003
Improved Machine
Reliability
Standardisation
rework
J
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Standardize Tooling
F M A M J
J A S O N D
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Fundamental Concept of Plant Effectiveness
16 Kinds of loss
8 availability losses
5 productivity losses
3 production/ cost losses
– not part of OEE -
Machine Failure
Management losses
Set up & adjustments
Motion
Loss of energy
Tool changes
Line organization
Die, Jig and tool losses
Start-up losses
Logistics
Minor stoppages
Adjustments
Yield losses
Speed Losses
Defects and Rework
Shutdown
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OEE (Overall Equipment Effectiveness)
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
Factory Pulse
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