OEE SAGW Management

1、OEE SAGW Management Review TPM Team OEE - Definition OEE (Overall Equipment Effectiveness) is a “best practices” metric for monitoring and improving the efficiency of your manufacturing processes (i.e. machines, cells, assembly lines, etc.). OEE is simple, practical and powerful. It takes the most c

2、ommon sources of manufacturing productivity losses and places them into three categories: Availability, Performance and Quality. In doing so, it distills complex production data into simple understandable metrics that provide a gauge for measuring true manufacturing efficiency. It also forms the fou

3、ndation for tools that help to improve productivity. OEE provides a consistent, proven way to measure the effectiveness of lean manufacturing initiatives, TPM (Total Productive Maintenance) programs and other productivity initiatives. 2 OEE - Definition Availability measures productivity losses from

4、 down time (events that stop planned production for an appreciable amount of time). Performance measures losses from slow cycles (factors that cause the process to operate at less than the maximum possible speed). Quality measures losses from manufactured parts that do not meet quality requirements.

5、 Together these three factors combine into one OEE score a single number that provides a complete measure of manufacturing efficiency and effectiveness. 3 OEE - Interpretation 100% Availability means the process has been running without any recorded stops. 100% Performance means the process has been

6、 consistently running at its theoretical maximum speed. 100% Quality means there have been no reject or rework pieces. 4 OEE Factors - Calculation 5 OEE Factors Planned Production Time 6 Plant Operating Time: the amount of time your facility is open and available for equipment operation. Planned Dow

7、n Time: includes all events that should be excluded from efficiency analysis because there was no intention of running production (e.g. Shift Start meetings/activities, breaks, lunch, scheduled maintenance, or periods where there is nothing to produce) Planned Production Time: is the remaining avail

8、able time between Plant Operating Time and Planned Down Time OEE Factors Planed Downtime: * Safety Talk * Warm Up * LAB * BPD * LAB * Error Proofing OEE Factors Calculation Summary OEE Factors Availability considers Down Time Loss, which includes any Events that stop planned production for an apprec

9、iable length of time (usually several minutes - long enough to log as a traceable Event). Examples: equipment failures, material shortages, and changeover time. Changeover time is included in OEE analysis, since it is a form of down time. While it may not be possible to eliminate changeover time, in

10、 most cases it can be reduced. 8 OEE Factors Performance takes into account Speed Loss, which includes any factors that cause the process to operate at less than the maximum possible speed, when running. Examples include machine wear, substandard materials, miss feeds, and operator inefficiency. Qua

11、lity takes into account Quality Loss, which accounts for produced pieces that do not meet quality standards, including pieces that require rework. 9 OEE Factors SAGW Planed Downtime: * Safety Talk * Warm Up * BPD * LAB * Error Proofing * Scheduled Maintenance 1. Define Planned Production Time SAGW M

12、anufacturing policies (Plant Manager - IE) OEE Factors 11 2. Consider the Ideal Run rate (Pieces/min) Estimate the Production per Shift based on the Operating Time If Downtime is Zero during the shift the Operating Time = Planned Production Time OEE Factors 12 OEE Factors 13 Is it possible to have a

13、n OEE value of 100%? OEE Factors 14 OEE Factors 15 OEE Factors 16 Downtime impact on OEE OEE Factors 17 Downtime impact on OEE and Poor Quality performance OEE Factors 18 OEE deterioration from 95.15% to 86.67% OEE Factors 19 OEE Factors 20 OEE - Factors Summary 21 OEENo. of pieces No. of Good piece

14、s Downtime (min.) AvailabilityPerformanceQuality 100%1651650100%100%100% 95.15%1651570100%100%95.15% 86.67%1511434591.82%99.67%94.60% 73.33%12912112078.18%100%93.80% 55.76%1009218066.27%90.09%92.00% OEE Plant / Line Calculation 22 How do I calculate OEE for my entire plant/ manufacturing line? This

15、is a very interesting and controversial topic. There are two reasonable options for calculating Plant OEE: Straight Average Weighted Average Straight Average Plant OEE: It is the simplest method and consist of calculate the average the OEE scores of all production assets (i.e. add together the OEE s

16、cores of all production assets and then divide that result by the number of production assets). In a plant with “n” production assets the calculation would be: OEE Plant= (OEE1 + OEE2 + + OEEn) / 3 OEE Plant / Line Calculation 23 Weighted Average Plant OEE: It is an improved (albeit more complex) me

17、thod. It consist of calculate a weighted average of the OEE scores of all production assets. A weighted average “weights” the OEE score of each production asset to take into account its relative importance. The weight can be any factor that assigns relative importance; however, it is recommended to

18、assign weights based on the value added by the production asset. Doing so, helps keep the focus on improvements that add the most value to the bottom line. In a plant with three production assets, the calculation would be: OEE Plant /Line = (OEE1 x Weight1) + (OEE2 x Weight2) + . + (OEEn x Weightn)

19、(Weight1 + Weight2 + + Weightn) OEE Plant / Line Calculation 24 Considerations: Manufacturing Line architecture Manufacturing Process Steps (Number of Stations) Operational Complexity Operation Criticality Factors that will affect productivity Safety Environmental Poor Quality Performance High Downtime Operator Skills and Knowledge Process adjustments complexity Tools availability Spare parts availability OEE Plant / Line Calculation 25