document.xls Observation 04/08/2023 03:58:53

SET-UP OBSERVATION FORM

Operator(s) M/c. Date

Start End From To Area / Department

Part No.

Operation time Change over categories Goal of improvement Plan

Changeover Element Element Elapsed External Internal Waste Improvement Plan Eliminate Reduce

Totals

Internal: Operations that necessitate the stopping of the machine. External: Operations not requiring the stopping of the machine.Key Terms: ASSEMBLE, DISMANTLE, USE, TAKE, TRANSPORT (FULL/EMPTY),PUT DOWN, FIND, ADJUST, INSPECT, REPOSITION, HOLD, WAIT, LOOK FOR.

Step No.

Internal to external

document.xls Spaghetti 04/08/2023 03:58:53

SPAGHETTI DIAGRAM Your Name:

Process Name: Location: Date:

document.xls Waste 04/08/2023 03:58:53

WASTE OBSERVATION Name:

Location: Date:

WASTE OBSERVED CAUSE

TRANSPORT

INVENTORY

MOTION

WAITING

OVERPRODUCTION

OVER PROCESSING

DEFECTS

document.xls Sequence 04/08/2023 03:58:53

SEQUENCE CHART Your Name:

Process Name: Location: Date:

PROCESS STEP

document.xls Load 04/08/2023 03:58:53

LOAD CHART Your Name:

Process Name: Location: Date: Operation

Operator

document.xls Graph 04/08/2023 03:58:53

GRAPH PAPER Your Name:

Graph Name: Date:

document.xls OEE Page 7 of 11 04/08/2023 03:58:53

OVERALL EQUIPMENT EFFECTIVENESS CALCULATION FORM

Date:

Process/Machine name:

Process/Machine number: Units of Time min/day(record average times lost across period observed)

Working Time (all recordings are for process / m/c stopped only)

Working Time: 480 min/day-

Planned meetings: min/day-

Planned lunches/breaks: 30 min/day-

Planned maintenance/stoppages: 10 min/day

Available Time: 440 min/day

Availability Rate

Available Time: 440 min/day-

45 min/day-

Process change over/set-ups: 50 min/day-

Start-up/waiting/unplanned meetings, breaks etc: 15 min/day

Operating Time: 330 min/dayAvailability Rate % 75.0%

Performance Rate

Operating Time: 330 min/day-

Idling, adjustments & minor stoppages: 16 min/day-

Performance loss: Process time for 1 part (actual): 20 Units of time

Process time for 1 part (optimal): 17.5 Units of time

difference: 2.5 Units of timeX

Units produced in period (all shifts): 20 partsPerformance loss: 50 min/day

Productive Time: 264 min/dayPerformance Rate % 80.0%

Quality Rate

Productive Time: 264 min/day-

Time for Rework: 30 min/day-

Time for Scrap (use % of productive time): 14 min/day-Effective Time: 220 min/day

Quality Rate % 83.3%Overall Equipment Effectiveness

Availability Rate % 75.0%X

Performance Rate % 80.0%X

Quality Rate % 83.3%

OEE 50.0%

Process/equipment failure:

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OVERALL EQUIPMENT EFFECTIVENESS ANALYSIS

Losses min/day

Breakdowns 45

Changeovers 50Start-up 15Idling 16

Speed 50

Scrap&rework 44

TOTAL LOSSES 220

Availability Rate 75.0%Performance Rate 80.0%Quality Rate 83.3%

OEE 50.0%

min/day

Availability Loss 110

Performance Loss 66

Quality Loss 44OEE 220

Availability Loss25%

Performance Loss15%

Quality Loss10%

OEE50%

OEE

Breakdowns

Changeovers

Start-up

Idling

Speed

Scrap&rework

0

10

20

30

40

50

60

document.xls Improvement 04/08/2023 03:58:53

IMPROVEMENT MONITOR Name:

Location: Date:

PARAMETERS UNITS BEFORE AFTER IMPV'T REMARKS

Changeover Time (last to first) Hrs

External Time Hrs

Internal Time Hrs

Number of Set-up Steps

Travel Distance (Man) M

Travel Distance (Mat'l) M

Travel Distance (Tools) M

Floor Space used

OEE %

Value Added/Total Time %

Number of people req. (all shifts)

Number of Error Proofs

5S Observation score %

3D Observation score %

M2

document.xls 5Why 04/08/2023 03:58:53

5 WHY ANALYSIS Name:

Problem/Issue: Date:

WHY 1 WHY 2 WHY 3 WHY 4 WHY 5

document.xls Action 04/08/2023 03:58:53

ACTION PLANDate:

Process/Location:Enter 0,1,2,3,4

No. Issue Action Who When Prog.

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