WELCOME

KAILAS SREE CHANDRANCLASS: S7 INDUSTRIAL 432

Guide: V REGIKUMAR

OVERALL EQUIPMENT EFFECTIVENESS

OEE

MODERN APPROACH TO

OVERALL EQUIPMENT EFFECTIVENESS

OEE

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Loss due to breakdown of equipment.

Loss is more than 10 minutes.

Biggest of SIX BIG LOSSES.

Tooling Failures

Unplanned Maintenance

General Breakdowns

Equipment Failure

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The time lost due to adjustmentsin the equipment.

Loss is less then 10 minutes.

Setup/ Changeover

Material Shortages

Major Adjustments

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Small stops losses occur when equipmentstops for a short time as a result of atemporary problem.

These includes stops that are under tenminutes. Component Jams

Misfeeds

Sensor Blocked

Delivery Blocked

Cleaning/ Checking

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Reduced speed refers to thedifference between Design speedand Actual Operating speed. Under Nameplate Capacity

Under Design Capacity

Due to Equipment Wear

Due to Operator Inefficiency

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Some equipments require warm-up time and certain adjustmentsto obtain optimum output.Startup rejection occurs duringthis startup time.

Scrap

Rework

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These losses occurs when productsproduced are not conforming to thespecifications.

These are rejects during steady-stateproduction.

Scrap

Rework

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The amount of time the facility is open andavailable for operation.

One year consists of 365 days, one dayconsists of 24 hours, 60 minutes in onehour, 60 seconds in one minute.

PLANT OPERATING TIME = FullyProductive Time + Quality Loss + SpeedLoss + Downtime Loss + PlannedShutdown

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PLANT OPERATING TIME

PLANNED PRODUCTION TIME PLANNED SHUTDOWN

OPERATING TIME DOWNTIME LOSS

NET OPERATING TIMESPEED LOSS

FULLY PRODUCTIVE TIMEQUALITY

LOSS

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OEE FACTORS

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Availability represents the percentageof scheduled time that the equipment isavailable to operate.

Availability takes into account DownTime Losses.

AVAILABILITY = Operating TimePlanned Production Time

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Performance represents the speed atwhich the equipment runs as apercentage of its designed speed.

Performance takes into account Speedloss.

PERFORMANCE = Net Operating TimeOperating Time

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Quality represents the Good unitsproduced as a percentage of the Totalunits produced.

QUALITY = Fully Productive TimeNet Operating Time

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QUALITY= Good Pieces/ Total Pieces

PERFORMANCE=Actual Run

Rate/ Ideal Run Rate

AVAILABILITY= Operating time/

Planned Production Time

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OEE= AVAILABILITY X PERFORMANCE X QUALITY

Availability = Operating Time / Planned Production Time

Performance = (Total Pieces / Operating Time) / Ideal Run Rate

Quality = Good Pieces / Total Pieces

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This method use computers foraccessing inputs, calculating OEEand its analysis.

E.g.: OEE IMPACT, VISUAL OEE,OEE TOOLKIT, PROVIDEAM etc.

Spreadsheets

System Software

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o Shift Length: 8 Hours

o Tea Breaks: 10 Minutes x 2

o Meals Break: 1 Hour

o Downtime: 10% of shift

o Idle Runrate: 5 pieces/minute (Cycle time=0.2min/pieces)

o Total Pieces Produced: 1600

o Rejected Pieces: 52

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OEE= Availability x Performance x Quality

Availability = Operating Time/ PlannedProduction Time

Planned Production Time = Plant OperatingTime – Planned Shutdown

Plant Operating Time= 8 hours x 60 = 480 min.

Planned Shut down = Tea break + LunchBreak = (10x2) + 60 = 80minutes.

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Planned Production Time = 480-80 = 400 min.

Operating Time = Planned Production Time-Downtime Loss = 400-48 = 352 minutes.

Availability = 352/400 = 0.88

Performance = (Total Pieces / Operating Time)/Idle Run Rate = (1600/352) / 5 = 0.9091

Quality = Good Pieces / Total Pieces= (1600-52) / 1600 = 0.9675

OEE = 0.88 x 0.9091 x 0.9675 = 0.774

OVERALL EQUIPMENT EFFECTIVENESS = 77.4%

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OVERALL EQUIPMENT EFFECTIVENESS (EXCEL CALCULATOR)

Production Data

Shift Length 8 Hours = 480 Minutes

Short Breaks 2 Breaks @ 10 Minutes Each = 20 Minutes Total

Meal Break 1 Breaks @ 60 Minutes Each = 60 Minutes Total

Down Time 48 Minutes

Ideal Run Rate 5 PPM (Pieces Per Minute)

Total Pieces 1,600 Pieces

Reject Pieces 52 Pieces

Support Variable Calculation Result

Planned

Production Time Shift Length - Breaks 400 Minutes

Operating Time Planned Production Time - Down Time 352 Minutes

Good Pieces Total Pieces - Reject Pieces 1,548 Pieces

OEE Factor Calculation OEE%

Availability Operating Time / Planned Production Time 88.00%

Performance (Total Pieces / Operation Time) / Ideal Run Rate 90.91%

Quality Good Pieces / Total Pieces 96.75%

Overall OEE Availability x Performance x Quality 77.40%

OEE FactorWorld

Class OEEOEE%

Availability 90.00% 88.00%

Performance 95.00% 90.91%

Quality 99.90% 96.75%

Overall OEE 85.00% 77.40%

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World class OEE is a standard which is used to compare the OEE of the firm.

OEE Factor WORLD CLASS

Availability 90%

Performance 95%

Quality 99%

Overall Equipment Effectiveness

85%

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FULLY PRODUCTIVE TIME

QUALITY LOSS

PLANT OPERATING TIME

PLANNED PRODUCTION TIME PLANNED SHUTDOWN

OPERATING TIME DOWNTIME LOSS

RUNNING TIMESTOP TIME

LOSS

NET OPERATING TIMESPEED LOSS

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Usability takes into account Stop TimeLoss.

USABILITY = Running TimeOperating Time

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OEE

Availability Usability Performance Quality

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o Shift Length: 8 Hours

o Tea Breaks: 10 Minutes x 2

o Meals Break: 1 Hour

o Warm-up Time: 20 minutes

o Equipment Breakdown(Tool Failure): 28 min.

o Idle Runrate: 5 pieces/minute (Cycle time=0.2min/pieces)

o Total Pieces Produced: 1600

o Rejected Pieces: 52

Downtime Loss of 48

minutes (10% of Shift)

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Availability = Operating Time/ Planned Production Time

Planned Production Time = 400 minutes

Operating Time = Planned Production Time-Breakdowns = 400-28 = 372 minutes.

Availability = 372/400 = 0.93

Usability = Running time / Operating Time

Running Time = Operating Time –Warm-up Time = 372-20 = 352 minutes.

Usability = 352 / 372 = 0.9462

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Performance =(Total Pieces / Operating Time) /Idle Run Rate = (1600 / 352) / 5 = 0.9091

Quality = Good Pieces / Total Pieces= (1600-52) / 1600 = 0.9675

OEE = Availability x Usability x Performance x Quality

OEE = 0.93 x 0.9462 x 0.9091 x 0.9675 = 0.774

Modified OVERALL EQUIPMENT

EFFECTIVENESS = 77.4%

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Anil S. Badiger, ‘A proposal: evaluation ofOEE and impact of six big losses’, Int. J.Process Management and Benchmarking,Vol.2, No. 3, 2008, pp 234-248.

Ravikumar M. M., ‘Improving EquipmentEffectiveness’, Int. Business Management,Vol. 3, No.2, 2008, pp 91-96.

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