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The Basics of OEEOverall Equipment Effectiveness

10.29.09

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What is OEE?

Best practices way to monitor and improveeffectiveness of manufacturing processes

Breaks productivity loss down into threemain categories

Results in metrics that can be monitoredand use for improvement

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What is OEE?

OEE Factors

Availability

Performance

Quality

Losses

Six major causes for effectiveness losses

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Starting Point

Total Plant Operating Time = Total hours available to run

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Starting Point

Total Plant Operating Time = Total hours available to run

-No intention of running i. e. breaks, lunch, schedule maintenance

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Starting Point

Total Plant Operating Time = Total hours available to run

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

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Starting Point

Total Plant Operating Time = Total hours available to run

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

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Starting Point

Total Plant Operating Time = Total hours available to run

Operating Time=Planned Prod. Time-waiting on fabric, changeovers Downtime Loss

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

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Starting Point

Total Plant Operating Time = Total hours available to run

Operating Time=Planned Prod. Time-waiting on fabric, changeovers Downtime Loss

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

-Machine wear, poor incoming quality, operator inefficiency

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Starting Point

Total Plant Operating Time = Total hours available to run

Net operating Time =Oper. Time-small stops, inability to run at spec Speed Loss

Operating Time=Planned Prod. Time-waiting on fabric, changeovers Downtime Loss

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

-Machine wear, poor incoming quality, operator inefficiency

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Starting Point

Total Plant Operating Time = Total hours available to run

Net operating Time =Oper. Time-small stops, inability to run at spec Speed Loss

Operating Time=Planned Prod. Time-waiting on fabric, changeovers Downtime Loss

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

-Machine wear, poor incoming quality, operator inefficiency

-Product that does not meet quality standards including rework

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Starting Point

Total Plant Operating Time = Total hours available to run

Net operating Time =Oper. Time-small stops, inability to run at spec Speed Loss

Fully Productive Time Quality Loss

Operating Time=Planned Prod. Time-waiting on fabric, changeovers Downtime Loss

Planned Production Time=Total hours- breaks, scheduled downtime Planned Shutdown

-No intention of running i. e. breaks, lunch, schedule maintenance

-Equipment failures, material shortages, changeovers

-Machine wear, poor incoming quality, operator inefficiency

-Product that does not meet quality standards including rework

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Another Way to Look at It

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Another Way to Look at It

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Another Way to Look at It

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Another Way to Look at It

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Another Way to Look at It

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Another Way to Look at It

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Yet Another Way to Look at It

Total Plant Operating Time / Total Time Available to Run

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Yet Another Way to Look at It

Total Plant Operating Time / Total Time Available to Run

Planned Production TimePlanned

Shutdown

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Yet Another Way to Look at It

Total Plant Operating Time / Total Time Available to Run

Planned Production TimePlanned

Shutdown

Operating TimePlanned

ShutdownDowntime

Loss

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Yet Another Way to Look at It

Total Plant Operating Time / Total Time Available to Run

Planned Production TimePlanned

Shutdown

Operating TimePlanned

ShutdownDowntime

Loss

Net Operating TimePlanned

ShutdownDowntime

LossSpeedLoss

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Yet Another Way to Look at It

Total Plant Operating Time / Total Time Available to Run

Planned Production TimePlanned

Shutdown

Operating TimePlanned

ShutdownDowntime

Loss

Net Operating TimePlanned

ShutdownDowntime

LossSpeedLoss

Fully Productive TimePlanned

ShutdownDowntime

LossSpeedLoss

QualityLoss

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Six Big Losses

OEE LossCategory Six Big LossCategory Example Comment

Down Time Loss

Breakdowns ToolingUnplanned Maintenance

General breakdowns

Threshold between breakdownand small stop

Setup andAdjustments

Set up / changeover

Material shortages

Operator shortage

Major adjustments

Warm up time

Addressed through set up timereduction

Speed Loss

Small Stops MisfeedsCleaning checking

Blocked delivery

Blocked sensor

Typically stops under 5 minutesand no maintenance

Reduced Speed Rough runningUnder capacity

Equipment wear

Operator inefficiency

Any factor contributing torunning at less than ideal speed

Quality Loss

Startup Rejects ScrapRework

Rejects due to startup, warm-up,adjustments

Production Rejects ScrapRework

Rejects while steady stateproduction

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Starting Point

OEE Loss OEE Factor

PlannedShutdown

Not part of OEE calculation

Down TimeLoss

Availability =Operating Time

Planned Production time

Speed Loss Performance =Net Operating Time

Operating Time

Quality Loss Quality =Good product

Total Product

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World Class OEE

OEE Factor World Class Metric

Availability 90.0%

Performance 95.0%

Quality 99.9%

OEE 85.0%

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Calculating OEE

Availability =

Performance =

Performance =

Quality=

OEE =

Operating TimePlanned Production Time

Ideal Cycle TimeOperating Time / Total Pieces

Total Pieces / Operating TimeIdeal Run Rate

Good Pieces

Total Pieces

Availability x Performance x Quality

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Example Calculation

Shift Length 8 hours = 480 minutes

Short Breaks 2 @ 15 minutes

Meal Breaks 1 @ 30 minutes Down Time 47 minutes

Ideal Run Rate 19 meters / minute

Total Yards 7,000 meters / shift Rejections 157 meters

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Example Calculation

Planned Production Time

Shift Length breaks = 480-60=420 minutes

Operating Time

Planned Production Time Downtime

= 420-47 = 373 minutes

Good Product

Total meters rejection Meters

= 7000-157 = 6930 Meters

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Example Calculation

Availability = = =Operating Time

Planned Production Time373 minutes420 minutes 0.8881

or88.81%

Performance = =Total Yardage / Operating TimeIdeal Run Rate

7000/373 minutes19 meters / minute

0.9877 or 98.77%=

Quality = = =Good yardageTotal yardage

6930 meters7087 meters

0.9778 or 97.78%

OEE = =

= 0.8577 or 85.77%

0.8881 x 0.9877 x 0.9778Availability x performance x quality