OVERALL EQUIPMENT EFFECTIVENESS
BALAKUMAR V
OEE - INTRODUCTIONOEE Formulated By Seiichi Nakajima in the Year of 1988.
OEE is the gold standard for measuring manufacturing productivity.
Measuring OEE is a Manufacturing Best Practice.
The Effectiveness of the Equipment is the Actual Output over the Reference Output.
Equipment Effectiveness Shows how Effectively an Equipment is Utilized.
Overall Equipment Shows the Effectiveness of a machine Compared to the Ideal Machine as a Percentage.
INTRODUCTION OEE is a Lean Manufacturing Tool and Universal Best Practice to
Monitor, Evaluate and Improve the Effectiveness of a Production Process.
The Primary Purpose is to Drive Improved Asset Performance.
The Use Of OEE Helps Improve Performance through Visualizing, Quantifying and Systematically Eliminating Sources of Production Loss.
OEE is the Single Metric for Identifying Losses, Benchmarking Progress and Improving the productivity of manufacturing equipment.
OEE = Availability x Performance x Quality
OEE- GuideOEE
Factors
Six Big Losses
World Class OEE
Formulas
OEEExamp
le
Visual OEE
OEE-FactorsPlant Operating Time
Quality Loss
Speed Loss
Down Time Loss
Time Availablei.e. LMI Mex 24hrs
Subtract•Equipment failure
•Mat. Shortages,•Changeover time
Subtract•Different material,
•machine wear, operator inefficiency
Subtract•Rework time
•Scrap
OEE Goal is to Maximize Fully Productive Time
Plant Operating Time
Operating Time
Net Operating Time
Fully Productive Time
PlannedShutdown
Subtract Lunch,Breaks, Maintenace
OEE LOSS OEE FactorPlanned Shutdown *Not part of the calculation
Down Time Loss *Availability=Ratio of Operating Time to Planned Production Time(Operating Time=Planned Production Time-Down Time Loss)*100% Availability means the process has been running without any recorded stops
Speed Loss *Performance= Ratio of Net Operating time to Operating Time(Net Operating Time=Operating Time-Speed Loss)*Interpreted as Ideal Cycle Time to Actual Cycle Time*100% Performance means the process has been consistently running at itstheoretical maximun speed
Quality Loss *Quality=Ratio of Fully Productive Time to Net Operating Time(Fully Productive Time=Net Operating Time-Quality Loss)*Interpreted as the ratio of Good Pieces to Total Pieces*100% Qaulity means there have been no reject or rework pieces
This factor can then drill down into productivity losses
Six Big LossCategory OEE Loss Category
Event Examples CommentBreakdowns Down Time Loss Tooling failures Unplanned
maintenance General breakdowns Equipment failure
There is flexibility to decide between a breakdown and small
stop
Set Up andAdjustments Down Time Loss Setup/changeover Material
shortages Operator shortages Major adjustments Warm-Up Time
This loss is adressed through set up reduction projects
Small Stops Speed Loss Obstructed product flowComponent jams Misfeeds Sensored blocked Delivery blockedCleaning / Checking
Typically includes stops that are under five minutes
Reduced SpeedSpeed Loss Rough running
Under nameplate capacity Under designed capacity Equipment wear Operator inefficiency
Anything that prevents the process running normal speed
1.Startup Rejects
2.Production Rejects
Quality Loss Scrap ReworkIn process damageIn process expiration Incorrect assembly
1.Rejects during warm up, start up and early production
2.Rejects during steady-state production
AVAILABILITY Availability Shows the Machine available duration for
manufacturing. In Other Words, How Much Time Our Machine is Available for
Manufacturing.Availability takes into account of Breakdown Losses.Downtime Losses Include Events or Incidents that lead to a
Stoppage of planned production for a considerable duration.After Removing Downtime, We can get Exact Operating
Duration of the Machine.
AVAILABILITY There Are Two Types of Downtime ( Planned & Unplanned)Planned Downtime – Lunch & Tea BreaksUnplanned Downtime – Unexpected Things are HappenExample of Unplanned Downtime :
(i) Equipment Failure
(ii) Material Shortage
(iii) Excess Change Overtime
AVAILABILITY Availability =
Available Time – Downtime (planned + Unplanned)
Available Time
480 – ( 50+30) 480 – 80 480 480
400 480
.833 x 100 = 83.33%
=
=
=
=
PERFORMANCE Performance Shows the excess time taken for manufacturing
as compared to Standard Operating Timing.
The Performance takes into account of Speed Losses.
The Speed Losses Includes any factor that leads to operating production with more cycle time than maximum permissible.
PERFORMANCEExamples of performance Losses :
(i) Low Speed of Part Loading / Unloading
(ii) Fatigue of the Operator
(iii) Excess Cycle Time in Manual Work, Etc…
PERFORMANCE PERFORMANCE =
Cycle Time x Produced Qty Available Time
2 x 180 400
360 400
= =
= 0.9 = 0.9x100 = 90%
QUALITY Quality Shows the Good Quality of Product.It takes into account the losses (loss due to the Manufacturing
of a bad part.Quality loss can only be present due to the manufacturing of a
defective part or Non-Conforming part.
QUALITY Availability =
Produced Qty - Scrap Qty Produced Qty
360– 9 351 360 360
.975 x 100 = 97.5%
= =
=
OEE
OEE = Availability x Performance x Quality OEE = 0.833 X 0.9 X .975
= 0.73095 X 100 = 73.1 %
Studies indicate that most manufacturing plants are around 60% performance in OEE. A world class is considered to be 85% or more.
Questions1.What is OEE?
2.Who is Derived OEE?
3.When it is Derived?
4.What is the Six Major Losses in OEE?
5.What is the Formula of OEE?
THANK YOU