the prime oee manager

8/13/2019 The Prime Oee Manager

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PRIMEs main activity is to work with manufacturing companies toassist them in improving equipment performance

The best measure for machine performance is OEE (Overall

Equipment Effectiveness)

PRIME was unable to find a simple set of tools that would measure

OEE performance, present the results at both strategic andoperational levels, provide an effective means to drive and manage a

continuous improvement programme, and provide tools for

managing a maintenance function in a manufacturing business (ie

CMMS functionality)

The PRIME OEE Manager was designed to fill the gap that exists

for a simple-to-use, fully-functioning piece of software that wouldcarry out all of these functions. It is based on Microsoft Access 2000

and can, therefore, be extended and modified by individual users to

meet their precise needs

(Please Left-Click when ready to move to the next slide)

Background to the PRIME OEE Manager


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1. OEE Data Entry System, with Reports and Graphs

2. Maintenance Management Module, including work control,

preventive maintenance and stores management.

2. Downtime Analysis Reports

3. Production and Cost Reports

4. Equipment Failure Analysis & Graphs

5. Tooling Management, including full audit reporting, and

overhaul scheduling

6. Production and Cost Reports

7. Failure Mode, Effect & Criticality Assessment Module (forengineering failures)

8. Root Cause Elimination (RCE) Module

9. Projects/Modifications Management OEE Reports &

Graphs


What is in the PRIME OEE Manager system?


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What is OEE?

OEE stands for OVERALL EQUIPMENT EFFECTIVENESS

= % Upt ime x % Eff ic iency x % Qual ity

Uptime = Planned Operating Time - (Downtime + Setup Time)

Planned Operating Time

Efficiency = Amount Produced .

Run Time x Standard Production Rate

Quality = Amount Produced - Amount of Defects/Rework

Amount Produced



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Scheduled Production CapacityAvailable Production Capacity

Achieved Throughput

Effective Operation

Good Quality Product

Less Downtime Losses =

Less Runrate Losses =

Less Quality Losses =

Possible Shift Hours (Factory Open) Less Unmanned Shifts =

Usual

Basis

For

Planned

Hours


A Model for OEE


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Why use OEE to measure performance ?

OEE incorporates the 3 primary areas of performance loss

- Loss of equipment availability through all causes(eg setup, breakdown, lack of labour, materials etc)

- Loss through rework or reject

- Loss through operational inefficiency, startup & shutdown

procedures, slow running, minor delays etc

Integrates the performance of plant with the performance of people

Is multi-factorial, therefore supports a trade-off approach toperformance improvement initiatives

Provides a strategic level view of factory performance for senior

management as well as cell level performance for line management

Provides a common set of numbers, from Senior Management to line

operative

Provides a common focus for objectives setting in all manufacturing

disciplines (production, engineering, logistics, quality)

Is used by virtually all world class companies

Provides one element of a performance-balanced scorecard of KPIs



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Some Typical Facts About OEE and Maintenance

Present PossiblePossible

Improvement

Maintenance

Involvement

Maintenance

Contribution

Uptime 84% 95% 11% 40% 4%

Quality 93% 98% 5% 30% 2%

Efficiency 64% 91% 27% 40% 11%

OEE 50% 85% 35% 14%

Value of Possible Maintenance-Related Benefit 1,389,057

Current Total Cost of Maintenance (Direct + Indirect) 1,889,057

Maintenance Cost Escalation Factor 3.8

Maintenance isusually responsible for


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(Please Left-Click when ready to see details of OEE Manager)


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On logging on to OEE Manager, you are offered the Selection Menu.

Users can run OEE Manager in an integrated manner, or operate any ofthe modules in standalone mode.

(Please left-click your mouse)

(Please Left-Click when ready to look at the System Navigator)


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The System Navigator offers a schematic look at how the modules are

related. You can move to any module from this view, or go directly from theSelection Menu.


(Please Left-Click when ready to go to the OEE Management Menu options)


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The OEE Management Menu comprises a data entry section, and a number

of sets of reports and charts.




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All Data Entries

use Drop-Down

boxes

There are 2 screen variants for

entering downtimeby event

time (shown) or by duration.



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At each point where a batch of parts has been made, or at

the end of each shift, the throughput is entered. This is the

total amount manufactured, including reject/waste.



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When parts are rejected, or committed for rework, this data

needs to be entered in the system



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Users can set up abbreviated menus for operator and craftsmen data entry



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(Please Left-Click when ready to view the OEE Reports menu)

THIS IS ALL OF THE DATA REQUIRED TO SUPPORT THE

GENERATION OF OEE REPORTS, AND TO CARRY OUT

CONTINUOUS IMPROVEMENT.

WE WILL FIRST LOOK AT SOME TYPICAL REPORTS FROM

THE SYSTEM


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There is a top level Strategic Performance Report that

presents top level data for Senior Management.

The next level of data is based on daily, weekly or monthly

views of OEE, Uptime, Throughput or Quality Performance.

The next slide shows the standard OEE Reports Menu,

followed by a typical Weekly OEE report

(Please Left-Click to see the OEE Reports Menu)

(Please Left-Click to see a typical OEE report)


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OEE PERFORMANCE by Week/Cell

Cell Description Week W/C Date Uptime Rate Quality OEE

Machines Area 3.23 2/06/2003 76.49% 79.95% 100.00% 61.16%

Machines Area 3.24 9/06/2003 70.28% 68.79% 100.00% 48.34%

Machines Area 3.25 16/06/2003 79.31% 56.59% 100.00% 44.88%

Machines Area 3.26 23/06/2003 75.31% 60.78% 100.00% 45.77%

Machines Area 3.27 30/06/2003 70.97% 45.64% 99.86% 32.34%

Machines Area 3.28 7/07/2003 62.43% 78.72% 99.94% 49.12%

Machines Area 3.29 14/07/2003 77.85% 50.42% 100.00% 39.25%

Machines Area 3.30 21/07/2003 60.40% 54.69% 100.00% 33.03%

Machines Area 3.31 28/07/2003 42.96% 68.59% 100.00% 29.47%

Machines Area 3.32 4/08/2003 47.56% 75.37% 100.00% 35.84%

Machines Area 3.33 11/08/2003 87.59% 64.55% 100.00% 56.54%

Machines Area 3.34 18/08/2003 92.14% 57.15% 100.00% 52.65%

Machines Area 3.35 25/08/2003 83.53% 67.06% 100.00% 56.02%

Machines Area 3.36 1/09/2003 95.89% 58.27% 100.00% 55.87%

This is only one of a range of different reports



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The Uptime, Throughput and Quality reports have a similar

layout but show more detail.

The same information can be available in graphical form,

that can be either viewed on screen, or printed.

The slide shows the standard Graphs Menu, followed by

typical Weekly OEE Graphs and Weekly Loss Charts

(Please Left-Click when ready to view the Graphs menu)

(Please Left-Click when ready to view the charts)


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There are a suite of reports for the following:

Downtime Reports, presented in either summary or detail

Engineering Reports, again in summary or detail form, that

provide analysis of fault types, fault causes, MTBF,Response Time ratios etc

Production Reports, presenting summaries and detail of

production and reject quantities by shift, day or week.

Reports for Cost of Downtime and Cost of Failure

(Please Left-Click when ready to view some typical reports)


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Summary Downtime by Category PageFor operations between 26/05/2003 and 20/12/2003

Equipment Downtime Category Response Time Repair Time Total DowntimeMag Star 1

Production 0.0 94.2 94.2Production Changeover 0.0 30.0 30.0Engineering 0.5 26.7 27.2

No Production Planned 0.0 10.4 10.4Internal Raw Mats 0.0 7.7 7.7

Packing Team Not Ready 0.0 5.9 5.9Awaiting QA 0.0 3.4 3.4

Total Downtime for Equipment 178.8Mag Star 2

Production 0.0 40.4 40.4Production Changeover 0.0 18.9 18.9Engineering 0.3 14.4 14.6

No Production Planned 0.0 5.1 5.1Packing Team Not Ready 0.0 5.1 5.1

Awaiting QA 0.0 2.6 2.6Internal Raw Mats 0.0 1.3 1.3External Raw Mats 0.0 0.5 0.5

Total Downtime for Equipment 88.4

(Please Left-Click when ready to view the next report, or move to the next slide)

Downtime by Stoppage CodeFor operations in the period: 26/05/2003 to 24/08/2003

Stoppage Type Dtime HrsMag Star 1

Changeover/Set-Up 84.8

Production Problem 29.0Mech Breakdown 25.4

Other Reason 15.3

Shortage of Labour 6.0

Lack of Parts 4.0

Awaiting QA 2.4

Packing Problem 2.1

PPM Work 1.8

Parts Problems 1.3

Total 172.1

Mag Star 2

Production Problem 23.8

Changeover/Set-Up 18.8

Other Reason 16.8

Mech Breakdown 11.3

Packing Problem 4.1

Shortage of Labour 4.0

Parts Problems 2.4Awaiting QA 2.0

Lack of Parts 0.6Total 83.8

Weekly Cell Downtimefor Selected Categories

For Downtime Categories between aa and zzW/C Date WeekNo Downtime Hrs

Machines Area

26/05/2003 3.22 0.8

2/06/2003 3.23 13.6

9/06/2003 3.24 21.7

16/06/2003 3.25 15.1

23/06/2003 3.26 18.0

30/06/2003 3.27 20.6

7/07/2003 3.28 27.414/07/2003 3.29 15.4

21/07/2003 3.30 28.9

28/07/2003 3.31 41.6

4/08/2003 3.32 38.2

11/08/2003 3.33 9.0

18/08/2003 3.34 5.7

Weekly Engineering Uptime Performance

WeekNo W/C Date Planned Hours Eng D/T Hours Eng Uptime

Machines Area

3.22 26/05/2003 14.84 0.0 100.00%

3.23 2/06/2003 58.02 1.3 97.71%

3.24 9/06/2003 72.86 0.0 100.00%

3.25 16/06/2003 72.86 13.1 82.06%

3.26 23/06/2003 72.86 3.8 94.85%3.27 30/06/2003 70.86 3.8 94.59%

3.28 7/07/2003 72.86 4.2 94.29%

3.29 14/07/2003 72.86 2.8 96.23%

3.30 21/07/2003 72.86 7.7 89.38%

3.31 28/07/2003 72.86 1.4 98.06%

3.32 4/08/2003 72.86 1.8 97.60%

3.33 11/08/2003 72.86 0.0 100.00%

3.34 18/08/2003 72.86 0.0 100.00%

3.35 25/08/2003 58.02 2.0 96.55%

3.36 1/09/2003 44.52 0.0 100.00%

Mean Time Between Downtime EventsFor downtime events in the period: 26/05/2003 and 20/12/2003

MTBD = Mean Time between Downtime Events MTTR = Mean Time to Repair

Planned Hrs Dtime Hrs No.B'downs MTBD(Hrs) MTTR(Hrs) Eng.UptimeMag Star 1 525 23.7 13 40 1.8 95.5%

Mag Star 2 525 12.1 6 87 2.0 97.7%

Downtime by Fault TypeFor operations between 26/05/2003 and 7/09/2003

Fault Type Total Lost Time

Machines AreaMag Star 1

Other Mechanical Failure 6.08Mechanical Fracture 4.58

Gasket Leakage 4.25

Hose/Pipe Failures 3.75

Mech Seal or Gland 3.41

Fastener Problems 2.50

Lubricator Problems 1.58

Chain Problems 1.00Mag Star 2

Chain Problems 9.23Other Mechanical Failure 2.33

Mech Seal or Gland 0.58

Mechanical Fracture 0.50

Total Lost Time for Cell: 39.79

Shift ProductionFor production in the period: 7/07/2003 and 13/07/2003

EarnedMade Returned Lost Hrs

Machines Area7/07/2003 Mon - Thurs 55124 Ribbon 10CM X 5M 6000 0 2.5

7/07/2003 Mon - Thurs 55020 Ribbon 1.25CM X 1M 2000 0 0.87/07/2003 Mon - Thurs 50051 Yellow scissors 16800 60 5.3

Totals for Day 24800 60 8.6

8/07/2003 Mon - Thurs 55990 Stopcock innards 1480 0 0.98/07/2003 Mon - Thurs 53100 Size 2 vent ring with end 3000 0 2.58/07/2003 Mon - Thurs 50051 Yellow scissors 23400 0 7.3


9/07/2003 Mon - Thurs 50051 Yellow scissors 16200 0 5.1


10/07/2003 Mon - Thurs 56780 Martin seal 1030 0 0.610/07/2003 Mon - Thurs 50051 Yellow scissors 9600 0 3.0


11/07/2003 Friday 50004 Cutdown scissors 24900 0 7.8



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There is also a range of operational reports covering production performance,

equipment slow-running, production and maintenance costs, and operator &

craftsmen efficiency, etc.

The PRIME OEE Manager also incorporates all of the tools required to manage an

engineering workload, and implement continuous improvement to achieve high

levels of equipment performance. These additional, standard features comprise:

Work Order Management

Preventive Maintenance Scheduling

Management of Maintenance SparesTooling Management

Failure Mode, Effect and Criticality Assessment(Designed specifically for Maintenance operations)

Root Cause Elimination

Management of Modifications and small Projects

Any of these sub-systems can be run in isolation of the OEE features (eg a clientcan use the work order and PPM management features alone, or only the FMEA

module etc).

For more information about these system features, select the Key Features tab in

one of the OEE web pages



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This short presentation has given you a very brief insight into the PRIME

OEE Manager system.

The PRIME OEE Manager is available free of charge to any PRIME client

You can obtain an onsite demonstration of the software, or a fully-

functional demonstration disc by contacting Frank Chambers by e-mail on

[email protected] or by phone on 044 (0)191 2364150

I hope that you have found the presentation informative.

On the next mouse click you will exit the presentation

the prime oee manager

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