PROMOTING RELIABILITY IMPROVEMENT in MANUFACTURING EQUIPMENT PRIME Engineering Services Welcome to this demo of the PRIME “OEE Manager” Select the Menu

• PRIME’s main activity is to work with manufacturing companies to assist them in improving equipment performance

• The best measure for machine performance is OEE (Overall Equipment Effectiveness)

• PRIME was unable to find a simple set of tools that would measure OEE performance, present the results at both strategic and operational levels, provide an effective means to drive and manage a continuous improvement programme, and provide tools for managing a maintenance function in a manufacturing business (ie CMMS functionality)

• The PRIME “OEE Manager” was designed to fill the gap that exists for a simple-to-use, fully-functioning piece of software that would carry out all of these functions. It is based on Microsoft Access 2000 and can, therefore, be extended and modified by individual users to meet their precise needs

(Please Left-Click when ready to move to the next slide)

Background to the PRIME “OEE Manager”

1. OEE Data Entry System, with Reports and Graphs

2. Maintenance Management Module, including work control, preventive maintenance and stores management.

2. Downtime Analysis Reports

3. Production and Cost Reports

4. Equipment Failure Analysis & Graphs

5. Tooling Management, including full audit reporting, and overhaul scheduling

6. Production and Cost Reports

7. Failure Mode, Effect & Criticality Assessment Module (for engineering failures)

8. Root Cause Elimination (RCE) Module

9. Projects/Modifications Management OEE Reports & Graphs


What is in the PRIME “OEE Manager” system?

What is OEE?

“OEE” stands for “OVERALL EQUIPMENT EFFECTIVENESS”

= % Uptime x % Efficiency x % Quality

Uptime = Planned Operating Time - (Downtime + Setup Time) Planned Operating Time

Efficiency = Amount Produced .Run Time x Standard Production Rate

Quality = Amount Produced - Amount of Defects/Rework Amount Produced


Scheduled Production Capacity

Available Production Capacity

Achieved Throughput

Effective Operation

Good Quality Product

Less Downtime Losses =

Less Runrate Losses =

Less Quality Losses =

Possible Shift Hours (“Factory Open”) Less Unmanned Shifts =

Usual BasisFor

Planned Hours


A Model for OEE

Why use OEE to measure performance ?

• OEE incorporates the 3 primary areas of performance loss- Loss of equipment availability through all causes

(eg setup, breakdown, lack of labour, materials etc)- Loss through rework or reject- Loss through operational inefficiency, startup & shutdown

procedures, slow running, minor delays etc

• Integrates the performance of plant with the performance of people

• Is multi-factorial, therefore supports a ‘trade-off’ approach to performance improvement initiatives

• Provides a strategic level view of factory performance for senior management as well as cell level performance for line management

• Provides a common set of numbers, from Senior Management to line operative

• Provides a common focus for objectives setting in all manufacturing disciplines (production, engineering, logistics, quality)

• Is used by virtually all ‘world class’ companies

• Provides one element of a ‘performance-balanced scorecard’ of KPIs


Some Typical Facts About OEE and Maintenance

Present PossiblePossible

ImprovementMaintenance Involvement

Maintenance Contribution

Uptime 84% 95% 11% 40% 4%

Quality 93% 98% 5% 30% 2%

Efficiency 64% 91% 27% 40% 11%

OEE 50% 85% 35% 14%

Value of Possible Maintenance-Related Benefit £1,389,057

Current Total Cost of Maintenance (Direct + Indirect) £1,889,057

MANUFACTURING COST STRUCTURE Maintenance Cost Escalation Factor 3.8

Maintenance is usually responsible for <40% of all downtime losses

Engineering Downtime usually represents < 20% of all equipment losses

Assume a typical SME with an annual manufacturing cost of £5M, an annual maintenance cost of £500k and

an OEE level of 50%

Assume that the constituents of the OEE performance are as below:


(Please Left-Click when ready to see details of “OEE Manager”)

• On logging on to “OEE Manager”, you are offered the Selection Menu. Users can run “OEE Manager” in an integrated manner, or operate any of the modules in standalone mode.

(Please left-click your mouse)

(Please Left-Click when ready to look at the System Navigator)

• The System Navigator offers a schematic look at how the modules are related. You can move to any module from this view, or go directly from the Selection Menu.


(Please Left-Click when ready to go to the OEE Management Menu options)

•The OEE Management Menu comprises a data entry section, and a number of sets of reports and charts.



All Data Entries use Drop-Down

boxes

There are 2 screen variants for entering downtime – by event time (shown) or by

duration.


At each point where a batch of parts has been

made, or at the end of each shift, the throughput

is entered. This is the total amount manufactured,

including reject/waste.


When parts are rejected, or committed for rework,

this data needs to be entered in the system


Users can set up abbreviated menus for operator and craftsmen data entry


(Please Left-Click when ready to view the OEE Reports menu)

THIS IS ALL OF THE DATA REQUIRED TO SUPPORT THE GENERATION OF OEE REPORTS, AND TO

CARRY OUT CONTINUOUS IMPROVEMENT.

WE WILL FIRST LOOK AT SOME TYPICAL REPORTS FROM THE SYSTEM

There is a top level Strategic Performance Report

that presents top level data for Senior

Management.

The next level of data is based on daily, weekly or

monthly views of OEE, Uptime, Throughput or

Quality Performance.

The next slide shows the standard OEE Reports

Menu, followed by a typical Weekly OEE report(Please Left-Click to see the OEE Reports Menu)

(Please Left-Click to see a typical OEE report)

OEE PERFORMANCE by Week/Cell

Cell Description Week W/C Date Uptime Rate Quality OEE

Machines Area 3.23 2/06/2003 76.49% 79.95% 100.00% 61.16%

Machines Area 3.24 9/06/2003 70.28% 68.79% 100.00% 48.34%

Machines Area 3.25 16/06/2003 79.31% 56.59% 100.00% 44.88%

Machines Area 3.26 23/06/2003 75.31% 60.78% 100.00% 45.77%

Machines Area 3.27 30/06/2003 70.97% 45.64% 99.86% 32.34%

Machines Area 3.28 7/07/2003 62.43% 78.72% 99.94% 49.12%

Machines Area 3.29 14/07/2003 77.85% 50.42% 100.00% 39.25%

Machines Area 3.30 21/07/2003 60.40% 54.69% 100.00% 33.03%

Machines Area 3.31 28/07/2003 42.96% 68.59% 100.00% 29.47%

Machines Area 3.32 4/08/2003 47.56% 75.37% 100.00% 35.84%

Machines Area 3.33 11/08/2003 87.59% 64.55% 100.00% 56.54%

Machines Area 3.34 18/08/2003 92.14% 57.15% 100.00% 52.65%

Machines Area 3.35 25/08/2003 83.53% 67.06% 100.00% 56.02%

Machines Area 3.36 1/09/2003 95.89% 58.27% 100.00% 55.87%

This is only one of a range of different reports


The Uptime, Throughput and Quality reports have

a similar layout but show more detail.

The same information can be available in

graphical form, that can be either viewed on

screen, or printed.

The slide shows the standard Graphs Menu,

followed by typical Weekly OEE Graphs and

Weekly Loss Charts(Please Left-Click when ready to view the Graphs menu)

(Please Left-Click when ready to view the charts)


There are a suite of reports for the following:

• Downtime Reports, presented in either summary

or detail

• Engineering Reports, again in summary or detail

form, that provide analysis of fault types, fault

causes, MTBF, Response Time ratios etc

• Production Reports, presenting summaries and

detail of production and reject quantities by shift,

day or week.

• Reports for Cost of Downtime and Cost of Failure

(Please Left-Click when ready to view some typical reports)

Summary Downtime by Category Page 1 of 1 For operations between 26/05/2003 and 20/12/2003

Equipment Downtime Category Response Time Repair Time Total Downtime

Mag Star 1 Production 0.0 94.2 94.2 Production Changeover 0.0 30.0 30.0 Engineering 0.5 26.7 27.2 No Production Planned 0.0 10.4 10.4 Internal Raw Mats 0.0 7.7 7.7 Packing Team Not Ready 0.0 5.9 5.9 Awaiting QA 0.0 3.4 3.4 Total Downtime for Equipment 178.8

Mag Star 2 Production 0.0 40.4 40.4 Production Changeover 0.0 18.9 18.9 Engineering 0.3 14.4 14.6 No Production Planned 0.0 5.1 5.1 Packing Team Not Ready 0.0 5.1 5.1 Awaiting QA 0.0 2.6 2.6 Internal Raw Mats 0.0 1.3 1.3 External Raw Mats 0.0 0.5 0.5 Total Downtime for Equipment 88.4

(Please Left-Click when ready to view the next report, or move to the next slide)

Downtime by Stoppage CodeFor operations in the period: 26/05/2003 to 24/08/2003

Stoppage Type D’time HrsMag Star 1

Changeover/Set-Up 84.8

Production Problem 29.0

Mech Breakdown 25.4

Other Reason 15.3

Shortage of Labour 6.0

Lack of Parts 4.0

Awaiting QA 2.4

Packing Problem 2.1

PPM Work 1.8

Parts Problems 1.3

Total 172.1

Mag Star 2Production Problem 23.8

Changeover/Set-Up 18.8

Other Reason 16.8

Mech Breakdown 11.3

Packing Problem 4.1

Shortage of Labour 4.0

Parts Problems 2.4

Awaiting QA 2.0

Lack of Parts 0.6

Total 83.8

Weekly Cell Downtimefor Selected CategoriesFor Downtime Categories between aa and zz

W/C Date WeekNo Downtime HrsMachines Area

26/05/2003 3.22 0.82/06/2003 3.23 13.69/06/2003 3.24 21.7

16/06/2003 3.25 15.123/06/2003 3.26 18.030/06/2003 3.27 20.67/07/2003 3.28 27.4

14/07/2003 3.29 15.421/07/2003 3.30 28.928/07/2003 3.31 41.64/08/2003 3.32 38.2

11/08/2003 3.33 9.018/08/2003 3.34 5.7

Weekly Engineering Uptime Performance

WeekNo W/C Date Planned Hours Eng D/T Hours Eng UptimeMachines Area

3.22 26/05/2003 14.84 0.0 100.00%

3.23 2/06/2003 58.02 1.3 97.71%

3.24 9/06/2003 72.86 0.0 100.00%

3.25 16/06/2003 72.86 13.1 82.06%

3.26 23/06/2003 72.86 3.8 94.85%

3.27 30/06/2003 70.86 3.8 94.59%

3.28 7/07/2003 72.86 4.2 94.29%

3.29 14/07/2003 72.86 2.8 96.23%

3.30 21/07/2003 72.86 7.7 89.38%

3.31 28/07/2003 72.86 1.4 98.06%

3.32 4/08/2003 72.86 1.8 97.60%

3.33 11/08/2003 72.86 0.0 100.00%

3.34 18/08/2003 72.86 0.0 100.00%

3.35 25/08/2003 58.02 2.0 96.55%

3.36 1/09/2003 44.52 0.0 100.00%

Mean Time Between Downtime EventsFor downtime events in the period: 26/05/2003 and 20/12/2003

MTBD = Mean Time between Downtime Events MTTR = Mean Time to Repair

Planned HrsD’time Hrs No.B'downsMTBD(Hrs) MTTR(Hrs)Eng.UptimeMag Star 1 525 23.7 13 40 1.8 95.5%

Mag Star 2 525 12.1 6 87 2.0 97.7%

Downtime by Fault TypeFor operations between 26/05/2003 and 7/09/2003

Fault Type Total Lost TimeMachines Area Mag Star 1

Other Mechanical Failure 6.08

Mechanical Fracture 4.58

Gasket Leakage 4.25

Hose/Pipe Failures 3.75

Mech Seal or Gland 3.41

Fastener Problems 2.50

Lubricator Problems 1.58

Chain Problems 1.00 Mag Star 2

Chain Problems 9.23

Other Mechanical Failure 2.33

Mech Seal or Gland 0.58

Mechanical Fracture 0.50

Total Lost Time for Cell: 39.79

Shift Production For production in the period: 7/07/2003 and 13/07/2003

Earned Made Returned Lost Hrs

Machines Area 7/07/2003 Mon - Thurs 55124 Ribbon 10CM X 5M 6000 0 2.5 7/07/2003 Mon - Thurs 55020 Ribbon 1.25CM X 1M 2000 0 0.8 7/07/2003 Mon - Thurs 50051 Yellow scissors 16800 60 5.3

Totals for Day 24800 60 8.6

8/07/2003 Mon - Thurs 55990 Stopcock innards 1480 0 0.9 8/07/2003 Mon - Thurs 53100 Size 2 vent ring with end 3000 0 2.5 8/07/2003 Mon - Thurs 50051 Yellow scissors 23400 0 7.3


9/07/2003 Mon - Thurs 50051 Yellow scissors 16200 0 5.1


10/07/2003 Mon - Thurs 56780 Martin seal 1030 0 0.6 10/07/2003 Mon - Thurs 50051 Yellow scissors 9600 0 3.0


11/07/2003 Friday 50004 Cutdown scissors 24900 0 7.8


There is also a range of operational reports covering production performance, equipment slow-running, production and maintenance costs, and operator & craftsmen efficiency, etc.

The PRIME “OEE Manager” also incorporates all of the tools required to manage an engineering workload, and implement continuous improvement to achieve high levels of equipment performance. These additional, standard features comprise:

Work Order ManagementPreventive Maintenance SchedulingManagement of Maintenance Spares

Tooling ManagementFailure Mode, Effect and Criticality Assessment

(Designed specifically for Maintenance operations)

Root Cause EliminationManagement of Modifications and small Projects

Any of these sub-systems can be run in isolation of the OEE features (eg a client can use the work order and PPM management features alone, or only the FMEA module etc).

For more information about these system features, select the “Key Features” tab in one of the OEE web pages


This short presentation has given you a very brief insight into the PRIME OEE Manager system.

The PRIME “OEE Manager” is available free of charge to any PRIME client

You can obtain an onsite demonstration of the software, or a fully-functional demonstration disc by contacting Frank Chambers by e-mail on

“[email protected]” or by phone on 044 (0)191 2364150

I hope that you have found the presentation informative.

On the next mouse click you will exit the presentation

Documents

PROMOTING RELIABILITY IMPROVEMENT in MANUFACTURING EQUIPMENT PRIME Engineering Services Welcome to this demo of the PRIME “OEE Manager” Select the Menu