Introduction to OEE Overall Equipment Effectiveness · 2007-10-15 · with current equipment, then...

Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Introduction to OEE

Overall Equipment Effectiveness

Ferry Hallewas

Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 2

Agenda

1. Introduction to OEE1. Introduction to OEE

2. Concepts & Challenges 2. Concepts & Challenges

3. RA answers to OEE3. RA answers to OEE

4. Case Studie4. Case Studie

5. Q & A5. Q & A


What is the correlation between efficiency, effectiveness and productivity?

Overall Equipment Effectiveness

Efficiency

Effectiveness

Process

Productivity

The final goal is to improve productivity The final goal is to improve productivity

Actual outputActual outputActual inputActual input

Reference input

Reference input

Reference output

Reference output

ReferenceProductivity


Where is OEE coming from?

• TPM (Total Productive Maintenance) has its genesis in the Japanese car industry in the 1970s

• OEE is one of the indicators of TPM • TPM embrace

– Equipment & Process Improvement– Maintenance Excellent Mgmt – Cross functional implementation (Management, Engineering, Operations,

Maintenance)– Continues improvement

Machine availabilty = 90% = Processavailability

90%

90%

90%

90%

Process availability = 90% * 90% * 90% * 90% = 66%

90%

90%

90%

90%

Process availability = 97% * 97% * 97% * 97% = 90%

97%

97%

97%

97%


OEE in Pharma

Source: IBM

OTIF: On Time In Full (Dilervery)

RFT: Right First Time

CpK: Process Capability Index

OEE: Overall Equipment Effectiveness


Calculating OEE

Total time (365days x 24 hours)

Theoretical Production Time Not scheduled

Planned Production Time PlannedDowntime

Gross Operating Time

Net Operating Time

UnplannedDowntime

Speedlosses

Valuable Operating Time Qualitylosses

OEE = Availability x Performance x QualityOEE = Availability x Performance x Quality

Availability

Quality

Performance

No Production. – “The factory is closed”

Not Planned to Run – 3 shifts ‘v’ 1 shift etc..

Machine Failure

Material/Operators issues

Machine Jam

Etc..

Machine not Running at Max Speed..

Goods Re-Work or Scrap

85.0%Overall OEE

99.9%Quality

95.0%Performance

90.0%Availability

World ClassOEE Factor

Source AMR


OEE in broader context

Total time (365days x 24 hours)

Theoretical Production Time Not scheduled

Planned Production Time PlannedDowntime

Gross Operating Time

Net Operating Time

UnplannedDowntime

Speedlosses

Valuable Operating Time Qualitylosses

OEE

Asset Utilization

Net Utilization

Capacity Utilization

Operation Effectiv.


From OEE to Operational Excellence

• You can’t improve what you can’t see!

• You can’t control what you can’t measure!

• You can’t optimize what you can’t control!

Mature available technologies - but focus has been elsewhere.


The “OEE” Data Challenge

• It is extremely troublesome to collect data manually

• Requires regular, timely feedback to the “floor “to be of value

• Data models and interpretation of data can be complex

• Quality• Availability• Efficiency

• Availability• MTBF• MTTR• Number of failures

Paper Records

EXCELHighLevel

Report

ERP

Logbook

ManualProcess

ManualOEEData

Collection


The "Technical” Challenge

Today

USEFUL INFO !!

Useful information is LOCKED

Packaging LinePackaging Line

Future

USEFUL INFO !!

Packaging LinePackaging Line

Useful information is AVAILABLE


So? What should an OEE tool look like?

üOn-demand visibility to Line performance for decision support and continuous process control improvement

üWeb-based reporting & analysis tools

ü Visibility and Control to Improve Operations

ü Track shift and operator performance by orderü Automated, accurate collection of line

production dataü Industry Standard (S95) data

collection & Storage with reconciliation functionality

ü Integration with MES

üReporting Flexibility to sort by…(Product, Shift, Operator, Work Order…)


Different needs, different reporting

Maintenance

Quality

WorkcenterShift

Product ID / SKUTotal PartsGood PartsScrap Parts

Stacked bar chart with Scrap and Good parts

by workcell

Tabular Chart ofquality data

Availability

WorkcenterShift

Product IDAvailable TimeRunning Time

Down TimeRun %

Down %

Downtime ReportBy Workcentercombined with Fault Summary

Downtime DetailsReport

Machine Mode Report“State Report”

Machine ModeDetails Report

Changeover Reports“Changeover”

Changeover DetailReport

Performance

Total PartsTheoretical Parts

Good PartsScrap Parts

Ideal Cycle TimeRunning Time

Throughput CapacityReports Changeover Reports

Machine Mode Report“State Report”

Machine ModeDetails Report

Engineering / QAOperations


Product, Process or Personnel???


Product, Process or Personnel???


Give me the details


Root cause analyses ….


What trends can I find (data mining)…


What you get out of OEE?

• Increased capacity– Increasing efficiency means that the company can produce more product

in the same amount of time with the same costs, which increases revenue and profits. This is dependent upon there being elastic demand for the products they produce.

• Decreased manufacturing costs– Increasing efficiency could result in a reduction in labor and other

variable manufacturing costs if, for example, overtime hours or even a complete shift can be eliminated. Costs are reduced while revenue is maintained, resulting in an increase in profits.

• Deferred capital expenditures– This is related to increased capacity. If more products can be produced

with current equipment, then the purchase of new equipment to increase output may be deferred, reducing capital expenditures. In a tightening economy the “cost of capital” could also be an issue.

• Decrease in the cost of quality– Increased quality is a component of increased efficiency. Raising quality

levels reduces cost in at least two ways: by reducing scrap, and by reducing the cost of product returns.


And Now …

How we can help….


RA’s Complete Solution for Life Sciences

MES

ERP

Automation

BuildingPower and Energy

Fill/FinishOSDBioreactorAPI

Water / Wastewater

Building Automation System

Qualified Building Automation System

Automation System

Batch System

Visualization / OEE

Recipe Management / Warehouse

3rd party Connectivity

Asset Management

Electronic Batch Record Weighing & Dispense

Historian

ERP

LIMS CAPA DMS Others


Solution: FactoryTalk Metrics

• Event collection, analysis and efficiency monitoring

• Customizable and scalable– Measure only what is important

• Reliable OPC-compliant data collection

• Efficient, open database storage• Access to all reports with a

browser


FactoryTalk Metrics Fundamentals

• A complete system for:– Event collection and analysis– Efficiency monitoring

• Customizable and scalable– Make it unique to your plant– Continuum from simple to complex;

small to large– Measure what is important to you

• Reliable, 24/7 data collection from any OPC-compliant devices from any manufacturer

• Data storage in an efficient, open database

• Access to all reports with a Web Browser

– Built-in HTML report writer– Built-in Web Server– Automatic website creation and

maintenance


FactoryTalk Metrics Default KPIs

• OEE• Availability %• Performance %• Quality %• MTBF (Mean Time Between Failure)• MTTR (Mean Time To Recover)• Failure Frequency Rate• Failure Rate

• More can be added using features in the product!

• Available % (vs. Schedule)• Good Parts %• Scrap Parts %• Ideal Capacity• Running %• Downtime %• Fault %


Results• OEE achieved for both dry

operations and packaging lines• Reduction in Manual Work

Entries• Continuous Quality

Improvement• Reduction in Maintenance

Costs

Resolution• IA provided a unified system to

connect the plant floor machinery with manufacturing information systems

• Automate data flow provided between the machines and the Automatic Productivity Tool

Analysis• Rockwell Automation

Consulting group studied current operations to determine an effective approach to address manufacturing productivity efficiencies

Integrated Productivity Tool Reduces Time to Market – Top 20 Pharma Company

Customer Issue• Needed to improve productivity

in both dry operations and packaging lines by implementing an Automatic Productivity Tool


Thank you !

Any questions?

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Introduction to OEE Overall Equipment Effectiveness · 2007-10-15 · with current equipment, then...

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