05194OEE Overall Equipment Effectiveness.ppt

Overall Equipment Effectiveness(OEE),Definitions and Calculations,Definitions,Overall Equipment EffectivenessA measure of the equipments effectiveness in producing parts.It is determined by three factors:Equipment AvailabilityPerformance EfficiencyQuality Rate,Definitions,Equipment Availability The efficiency of the machine with respect to the time the machine was available.Performance Efficiency A measurement of both speed losses and losses associated with idling or minor interruptions resulting from blocked or starved conditions.Quality Rate The efficiency of the machine with respect to the number of defects produced.,Definitions,Total Available Time The total time from start of shift to end of shift.Planned Downtime The time the machine is down due to contractual breaks.Net Available Time The time the equipment is planned to operate during the shift.,Definitions,Operating Time The time that the equipment actually operates.Net Operating Time Operating time less the Starved&Blocked time.Note:Starved&Blocked losses affect machine performance,not availablity.,Definitions,Total Parts Run The total number of parts produced on the machine during the shift(including defects).Total Defects The total number of rejected,reworked,or scrapped parts produced during the shift.,Definitions,Ideal Cycle Time(seconds per part)The lesser of(i.e.the better of):The design cycle time of the machineThe best cycle time ever achieved and sustained on the machineAn estimate based on experience with similar machinesActual Cycle Time The part-to-part time the machine is running at.,Definitions,Breakdown Time The total time the machine is stopped because of malfunction.Includes the time that the machine is being repaired and tested,until it is ready to operate.Setup Time The total time that the machine is stopped to prepare to run a different part or to alter the machine to meet end product specifications.,Definitions,Tool Change Time The total time that the machine is stopped due to failure,breakage,deterioration,or wear of a machine tool.Stop Time The total time the machine is stopped due to interruptions in the process flow requiring operator or job setter intervention.,Definitions,Starved and Blocked Time The total time the machine is stopped due to starved and blocked conditions.Startup Time The total time the machine is stopped,irrespective of cause,during the first hour of the shift.,Definitions,Speed LossesThe lost production time resulting from the operation of the equipment at less than ideal speed.Idling&Minor Stoppage Losses The lost production as a result of minor interruptions in the process flow(losses due to Starved&Blocked conditions).,Sample Baseline Input Data,Total Available Time1100 minPlanned Downtime 100 minBreakdowns*100 minSetup*100 minTool Change*200 minStops*100 min Starved&Blocked*50 minStartup 50 min*=Includes Startup values,Sample Baseline Input Data,Total Parts Run 350 piecesTotal Defective Parts 50 piecesIdeal Cycle Time 0.5 min/pieceActual Cycle Time 1.0 min/piece,OEE Calculations(Launch Plan Page 10),Net Available Time=Total Available Time-Planned Downtime=1100-100=1000 minDowntime=Breakdowns+Setup+Tool Change+Stops=100+100+200+100=500 minOperating Time=Net Available Time-Downtime=1000-500=500 min,OEE Calculations,Equipment Availability=Operating Time/Net Available Time*100=500/1000*100=50%Performance Efficiency=(Ideal Cycle Time*Total Parts Run)/Operating Time*100=(0.5*350)/500*100=35%Quality Ratio=(Total Parts Run-Total Defective Parts)/Total Parts Run*100=(350-50)/350*100=85%,OEE Calculations,Overall Equipment Effectiveness=Equipment Availability*Performance Efficiency*Quality Ratio/10000=50*35*85/10000=15%,Major Losses Calculations-Pieces,Breakdown=Breakdowns(min)/Ideal Cycle Time=100/0.5=200 piecesSetup=Setup(min)/Ideal Cycle Time=100/0.5=200 piecesTool Change=Tool Change(min)/Ideal Cycle Time=200/0.5=400 pieces,Major Losses Calculations-Pieces,Stops=Stops(min)/Ideal Cycle Time=100/0.5=200 piecesStarved&Blocked=Starved&Blocked(min)/Ideal Cycle Time=50/0.5=100 piecesStartup=Startup/Ideal Cycle Time=50/0.5=100 pieces,Major Losses Calculations,Net Operating Time=Net Available Time-Downtime-Starved&Blocked=1000-500-50=450 minAverage Time Per Part=Net Operating Time/Total Parts Run=450/350=1.29 min/piece,Major Losses Calculations,Speed Loss(pieces)=(Net Operating Time/Ideal Cycle Time)-(Net Operating Time/Actual Cycle Time)=(450/0.5)-(450/1.0)=450 piecesSpeed Loss(time)=Speed Loss(pieces)*Ideal Cycle Time=450*0.5=225 minDefect Loss(time)=Total Defects(pieces)*Actual Cycle Time=50*1=50 minNote:Defects are losses in real time so they are calculated using actual cycle time.,Major Losses Calculations,Unidentified Loss(time)=Net Operating Time-(Total Parts Run*Actual Cycle Time)=450-(350*1.0)=100 minUnidentified Loss(pieces)=(Net Operating Time/Actual Cycle Time)-Total Parts Run=(450/1.0)-350=100 pieces,Major Losses Calculations,Ideal Cycle Parts=Net Available Time/Ideal Cycle Time=1000/0.5=2000 pieces=Breakdown+Setup+Tool Change+Stops+Starved&Blocked+Speed Loss+Unidentified+Total Parts Run=200+200+400+200+100+450+100+350=2000 pieces,TPM Major Losses Calculations,Jobs Per Hour=Total Parts Run/Net Operating Time*60=350/450*60=46.7 pieces/hourAchieved Jobs Per Hour=Total Parts Run/Net Available Time*60=350/1000*60=21 pieces/hourJobs Lost Per Hour due to Breakdowns=Breakdowns(pieces)/Net Available Time*60=200/1000*60=12 pieces/hour,TPM Major Losses Calculations,Jobs Lost Per Hour due to Setup=Setup(pieces)/Net Available Time*60=200/1000*60=12 pieces/hour Jobs Lost Per Hour due to Tool Change=Tool Change(pieces)/Net Available Time*60=400/1000*60=24 pieces/hourJobs Lost Per Hour due to Stops=Stops(pieces)/Net Available Time*60=200/1000*60=12 pieces/hour,TPM Major Losses Calculations,Jobs Lost Per Hour due to Starved&Blocked=Starved&Blocked(pieces)/Net Available Time*60=100/1000*60=6 pieces/hourJobs Lost Per Hour due to Speed=Speed Loss(pieces)/Net Available Time*60=450/1000*60=27 pieces/hourJobs Lost Per Hour due to Startup=Startup(pieces)/Net Available Time*60=100/1000*60=6 pieces/hour,TPM Major Losses Calculations,Jobs Lost Per Hour due to Unidentified Loss=Unidentified Loss(pieces)/Net Available Time*60=100/1000*60=6 pieces/hourJobs Lost Per Hour due to Defects=Total Defective Parts/Net Available Time*60=50/1000*60=3 pieces/hour,Measurables OEE Calculation Worksheet,AvailabilityA.Total Scheduled Time _minutesB.Required Downtime _minutes(Contractually Required Breaks+Paid Lunch)C.Net Available Time(A-B)_minutes,Measurables OEE Calculation Worksheet,D.All Other Downtime _minutes(Breakdowns+Setups&Adjustments+Tool Changes+Minor Stoppages+Meeting+Scheduled Maintenance)E.Operating Time(C-D)_minutesF.Availability(E/C)_%,Measurables OEE Calculation Worksheet,Performance EfficiencyG.Total Parts Run _partsH.Ideal Cycle Time_min/partJ.Performance Efficiency(H*G/E)_%,Measurables OEE Calculation Worksheet,Quality RateK.Total Defects _partsL.Quality Rate(G-K/G)_%M.Overall Equipment Effectiveness(F*J*L)_%,Mapping Measurables,TermMeasurables TermTotal Available Time.Total Scheduled TimePlanned Downtime.Contractually Required DowntimeSetup Time.Setup&Adjustment LossesTool Change Time.Tooling LossesStop Time.Documented Minor Stoppage Losses,Mapping Measurables,Planned Downtime Definition:MeasurablesPlanned Downtime=meetings and planned maintenance and is included in Downtime.OEE V3.3Does not account for meetings and planned maintenance.This can be recorded as a parameter under any downtime category.,Equipment,Seven MajorLosses,OEE Term,Total Available/Running Time(Production Shift Start to Shift End Time),Net Available Time/Loading Time Planned Down Time,Operating Time Downtime Loss,Net Operating SpeedTime Losses,Valuable Operating Defect Time Losses,7.Defects,5.Reduced Speed6.Idling&minor stops,1.Breakdown2.Tool Change3.Setup&Adj.4.Stops,QUALITY,PERFORMANCE,AVAILABILITY,