overall equipment effectiveness
DESCRIPTION
Overall Equipment Effectiveness presentationTRANSCRIPT
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KAILAS SREE CHANDRANCLASS: 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
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The time lost due to adjustmentsin the equipment.
Loss is less then 10 minutes.
Setup/ Changeover
Material Shortages
Major Adjustments
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Small stops losses occur when equipmentstops for a short time as a result of atemporary problem.
These includes stops that are under tenminutes. Component Jams
Misfeeds
Sensor Blocked
Delivery Blocked
Cleaning/ Checking
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Reduced speed refers to thedifference between Design speedand Actual Operating speed. Under Nameplate Capacity
Under Design Capacity
Due to Equipment Wear
Due to Operator Inefficiency
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Some equipments require warm-up time and certain adjustmentsto obtain optimum output.Startup rejection occurs duringthis startup time.
Scrap
Rework
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These losses occurs when productsproduced are not conforming to thespecifications.
These are rejects during steady-stateproduction.
Scrap
Rework
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The amount of time the facility is open andavailable for operation.
One year consists of 365 days, one dayconsists of 24 hours, 60 minutes in onehour, 60 seconds in one minute.
PLANT OPERATING TIME = FullyProductive Time + Quality Loss + SpeedLoss + Downtime Loss + PlannedShutdown
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PLANT OPERATING TIME
PLANNED PRODUCTION TIME PLANNED SHUTDOWN
OPERATING TIME DOWNTIME LOSS
NET OPERATING TIMESPEED LOSS
FULLY PRODUCTIVE TIMEQUALITY
LOSS
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OEE FACTORS
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Availability represents the percentageof scheduled time that the equipment isavailable to operate.
Availability takes into account DownTime Losses.
AVAILABILITY = Operating TimePlanned Production Time
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Performance represents the speed atwhich the equipment runs as apercentage of its designed speed.
Performance takes into account Speedloss.
PERFORMANCE = Net Operating TimeOperating Time
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Quality represents the Good unitsproduced as a percentage of the Totalunits produced.
QUALITY = Fully Productive TimeNet Operating Time
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QUALITY= Good Pieces/ Total Pieces
PERFORMANCE=Actual Run
Rate/ Ideal Run Rate
AVAILABILITY= Operating time/
Planned Production Time
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OEE= AVAILABILITY X PERFORMANCE X QUALITY
Availability = Operating Time / Planned Production Time
Performance = (Total Pieces / Operating Time) / Ideal Run Rate
Quality = Good Pieces / Total Pieces
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This method use computers foraccessing inputs, calculating OEEand 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
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OEE= Availability x Performance x Quality
Availability = Operating Time/ PlannedProduction Time
Planned Production Time = Plant OperatingTime – Planned Shutdown
Plant Operating Time= 8 hours x 60 = 480 min.
Planned Shut down = Tea break + LunchBreak = (10x2) + 60 = 80minutes.
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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)/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%
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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
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%
OEE FactorWorld
Class OEEOEE%
Availability 90.00% 88.00%
Performance 95.00% 90.91%
Quality 99.90% 96.75%
Overall OEE 85.00% 77.40%
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World class OEE is a standard which is used to compare the OEE of the firm.
OEE Factor WORLD CLASS
Availability 90%
Performance 95%
Quality 99%
Overall Equipment Effectiveness
85%
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FULLY PRODUCTIVE TIME
QUALITY LOSS
PLANT OPERATING TIME
PLANNED PRODUCTION TIME PLANNED SHUTDOWN
OPERATING TIME DOWNTIME LOSS
RUNNING TIMESTOP TIME
LOSS
NET OPERATING TIMESPEED LOSS
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Usability takes into account Stop TimeLoss.
USABILITY = Running TimeOperating Time
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OEE
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
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
Downtime Loss of 48
minutes (10% of Shift)
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Availability = Operating Time/ Planned Production Time
Planned Production Time = 400 minutes
Operating Time = Planned Production Time-Breakdowns = 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 ofOEE and impact of six big losses’, Int. J.Process Management and Benchmarking,Vol.2, No. 3, 2008, pp 234-248.
Ravikumar M. M., ‘Improving EquipmentEffectiveness’, Int. Business Management,Vol. 3, No.2, 2008, pp 91-96.
www.bestmanagementarticles.com
www.maintenanceworld.com
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