Measure the efficiency of the machine during its loading time

1. Overall Equipment Effectiveness (OEE) Measure the efficiency of the machine during its loading time Anand Subramaniam

2. 2 “Experience is directly proportional to the amount of equipment ruined.” - Harrisberger's Fourth Law of the Lab

3. Overall Equipment Effectiveness OEE figures are determined by combining the availability and performance of the equipment with the quality of parts made OEE measures the efficiency of the machine during its loading time. Planned downtime does not effect the OEE figure 3

4. Overall Equipment Effectiveness (OEE) 4

5. Equipment Losses 5 Speed Loss Reduced speed Minor stopping Down Time Loss Set-up / adjustments Equipment failure / breakdowns Quality Loss Rework / scrap Process errors

6. Material & Manpower Losses 6 Material Loss Material yield Energy losses Manpower Loss Waiting Instructions Waiting Materials Waiting Quality Confirmation Cleaning & Checking

7. Set-up Availability losses Breakdown Minor Stoppages Performance losses Speed losses Start-up losses Quality losses In process losses Losses – Example Inconsistent Times, Insufficient skills. Poor Planning & scheduling, Different methods, Poor tooling, Poor start up controls, Missing parts, Insufficient support, Excess start-up adjustment 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 Overall Equipment Effectiveness Unclear design specs., poor maintenance history, incorrect settings, Poor Training, Speed deliberately reduced, inconsistent Material Poor machine changeover, Inconsistent materials, No start-up check lists, Waiting for temp. - pressures, Minor adjustments Temperature & pressure changes, inconsistent materials, Process not followed, poor calibration, Gauges not calibrated properly.

8. OEE Calculation 8 OEE = Availability *performance * Quality yield Availability (Down Time Loss) = Time available for production - Downtime Time available in production Performance (Speed Loss) = Ideal cycle time x processing quantity Operating time Quality Yield (Quality Loss) = Total processed quantity – defect Total processed quantity

9. OEE Worked Example = Load – Down Time Load Time 460 min – 60 min 460 Time x Processed Qty Operating Time 0.5/ unit x 400 units 400 minutes Processed Amount – Amount of Defects Processed Amount 400 – 8 400 x 100% = 87% x 100% = 50% x 100% = 98% 1. Unexpected Eq. Breakdown 2. Set-up & adjustments 3. Idling and minor stoppages 4. Reduced speed 5. Defects in Process 6. Reduced Yield Availability : Performance Quality Yield ] ] = OEE = .87 x .50 x .98 = 46.2 % ] =

10. 10 “Skiing consists of wearing $3,000 worth of clothes and equipment and driving 200 miles in the snow in order to stand around at a bar and drink.” - P. J. O'Rourke

11. 11 Good Luck http://www.linkedin.com/in/anandsubramaniam