*OVERALL EQUIPMENT EFFECTIVENESS (O E E)A practical approach to problem solving & increasing Maintenance CircleClick mouse or any key to continue

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*HOW IS YOUR MACHINES MEASURED ?PROCESSED OUTPUT / PLANNED OUTPUT ?ACHIEVED HOURS / PLANNED HOURS ?ACTUAL DELIVERY / PLANNED DELIVERY ?QUANTITY ACCEPTED / (QUANTITY ACCEPTED + QUANTITY REJECTED ) ?Any other method...

Over last 3 months, was your machine more than 85% ?Over last 3 months, was your machine downtime less than 3% ?Are your customers happy with your product & delivery ?

If your answer is YES or NO to above questions, its time to measure O E E Maintenance Circle

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*What is O E E ?Overall Equipment Effectiveness is a measure of equipments NETT efficiency taking into account, following six major losses, advocatedin TPM

BREAKDOWN LOSSESSET UP & ADJUSTMENT LOSSESIDLING & MINOR STOPPAGESSPEED LOSSESREDUCED YIELDQUALITY REWORK / REJECTSMaintenance Circle

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*BREAKDOWN LOSSESSporadic stoppage of machineUn-noticed failure of certain componentsAccelerated deterioration of equipmentRepetition of certain problems, during productionMajor downtimes affecting productionFunction loss & Function reductionMaintenance Circle

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*SET UP & ADJUSTMENT LOSSESRepeated adjustments of process parameters during productionNon-standard approach to tool / process settingFrequent order changes on a machineRepetition of certain problems, during productionMajor downtimes affecting productionMaintenance Circle

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*IDLING & MINOR STOPPAGESRepeated jams / sensor failures / robot malfunctionsShortage of supporting materials: packing material, palettes, trolleys to name a fewNo fault indication, when machine stops leading to confusionMachine running without actual output (idling)Shift change-overMaintenance Circle

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*SPEED LOSSESMachine running slower than designed or desired speedProcess slowing down due to downstream limitationsMachines inability to withstand the designed or desired speedPast experienceFear of producing rejectionsMaintenance Circle

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*REDUCED YIELDToo many stops & starts resulting in reduced stabilization periodProcess limiting ramp-up & ramp-down time, reducing outputUp stream or down stream process limiting the ramp-up & ramp down periods.Maintenance Circle

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*QUALITY REWORK & REJECTSDuring every start-up (and sometimes, during stopping also), machine produces rejectionEnd product rejected due to various reasonsRejection at customers site due to various reasonsMeasuring system not consistent with process resulting in increased sampling quantitiesToo many reworks before finishing the productMaintenance Circle

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How to calculate O E E ?*Maintenance CircleOpen the attached excel-sheet object to calculate & understand O E E for two applications. Of course, once you understand the concept, it can be calculated to almost all applicationsCertain parameters need to be measured and recorded for correctly calculating OEE. The measures could be obtained from production records, measuring instruments, machine control system. Correct parameters must be decided upon to calculate realistic OEE.

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How to achieve higher O E E ?Start recording all the relevant data from production:Planned hoursActual run hoursMachine breakdownStoppages due to material, pallet change, shift change etc.Quantity rejected in process, in inspection, at dispatch and possibly from customers endDivide the data into various segments of Production, Maintenance & QualityStart measuring O E E for 4 to 6 weeks continuously and study the weak linksCreate small teams to work on individual weak links that contribute to O E E Fine tune the data / targets from time-to-time*Maintenance Circle

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*Hidden benefits of O E E Increase in productivity without huge monetary investment; of course time and people will be involvedAll hidden losses will be made visible ensuring better clarity Increase in profit margin of the company: Remember, O E E is one of the best methods of achieving profits without hurting the bottom lineReduced customer complaintsReduced breakdowns in machineLast but not least, it saves power to the organization, since machines are run efficientlyMaintenance Circle

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Thank You*Maintenance Circle

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