10 Overall Equipment Effectiveness

Lean Six Sigma Operational - Delegate Workbook

13

What target? Best of best Note the Best recording for “Availability”: Week No 1 2 3 4 5 6 7

Availability 0.80 0.90 0.85 0.70 0.75 0.95 0.92

Performance 0.80 0.85 0.87 0.92 0.89 0.92 0.85

Quality 0.99 0.98 0.98 0.99 0.97 0.90 0.96

OEE 0.63 0.75 0.72 0.64 0.65 0.79 0.75

SSG06101ENUK – Delegate Slides/Issue 1.1/ April 2008

14

What target? Best of best Note the Best recording for “Performance”: Week No 1 2 3 4 5 6 7

Availability 0.80 0.90 0.85 0.70 0.75 0.95 0.92

Performance 0.80 0.85 0.87 0.92 0.89 0.92 0.85

Quality 0.99 0.98 0.98 0.99 0.97 0.90 0.96

OEE 0.63 0.75 0.72 0.64 0.65 0.79 0.75


SSG06101ENUK - OEE/Issue 1.1 / April 2008

7

©The British Standards Institution 2008


15

What target? Best of best Note the Best recording for “Quality”: Week No 1 2 3 4 5 6 7

Availability 0.80 0.90 0.85 0.70 0.75 0.95 0.92

Performance 0.80 0.85 0.87 0.92 0.89 0.92 0.85

Quality 0.99 0.98 0.98 0.99 0.97 0.90 0.96

OEE 0.63 0.75 0.72 0.64 0.65 0.79 0.75


16

What target? Best of best Apply the “Best of the Best”: Week No 1 2 3 4 5 6 7

Availability 0.80 0.90 0.85 0.70 0.75 0.95 0.92

Performance 0.80 0.85 0.87 0.92 0.89 0.92 0.85

Quality 0.99 0.98 0.98 0.99 0.97 0.90 0.96

OEE 0.63 0.75 0.72 0.64 0.65 0.79 0.75

0.95

0.92

0.99

0.87



8



17

What target? Best of best • The “Best of the Best” indicate what is possible & the question asked is: 





Why this OEE performance is not achieved all the time? The Best of Best can be a short term target but if OEE is low we’ll need to get beyond this Often - in the short term there is no target. OEE is a diagnostic Tool - we’ll see what we get - understand root causes and set targets for improvement SSG06101ENUK – Delegate Slides/Issue 1.1/ April 2008

18

An example • OEE at ……………….

• Consider the 3 components of OEE…….



9



19

Availability

% Plant Availability = Planned Runtime - Downtime x 100 Planned Runtime


20

Planned Run Time • Shift duration 

days 07:15 - 17:00 = 9 hrs 45 mins



shifts 06:00 - 14:00; 14:00 - 22:00 = 8 hrs



add in Overtime

• Breaks 

Tea Break 15 mins



Lunch Break 30 mins

We know that team meetings, walking to breaks, washing, etc will eat into OEE. Remember that 85% is a world class auto factory where lockers, canteen ,etc are lineside.

45 mins If on shifts planned run time is 7hrs 15mins. 435minutes

• Down Time 

Change Overs



Stoppages - more than 10mins



10



21

Down Time • The plant suffered: • 3 minor breakdowns less than 10 minutes – these are neglected ~(counted as performance) • A major breakdown of 1 hour


22

Availability Availabili ty = Availabili ty =

Running Time − DownTime RunningTime 435 − 60 435

×

×

100%

100 = 86.3%



11



23

Machine Run Rate •

Determine the “Machine Run Rate”………..

•

Time the number of items produced by the machine in a minute…………...

•

The plant has been timed at producing 8 off items per minute, therefore…………

•



Machine Run Rate = 1 minute / 8



Machine Run Rate = 0.125 minutes

Remember: Full Speed – no allowances


24

Performance • Suppose in the day we produced 1200 items • % Performance = Machine Run rate x Processed Amount x 100 Operating Time

ie

.125 mins / Unit x 1200 Units x 100 435-60 mins

% Performance = 56.25%



12



25

Quality - Right First Time

% of Right First Time Products

=

Processed Amount - Defective Amount x 100 Processed Amount.

• Suppose 40 items (of the 800) failed inspection and were scrapped: % of Right First

=

Time Products

800 - 40 x 100 800

=

95%


26

Overall OEE OEE

=

Availabili ty × Performance × Quality × 100%

OEE

=

.863 × .5625 × .95 = 46.12%

• Why did the breakdown occur? • Why did it take an hour to fix? 

Did the fitter turn up quickly? Did he have the part needed for repair to hand?

• Did the crew take a break when the machine was down (rather than at the “appointed time” when it was back up again)? • What can be done to reduce a 5% scrap rate?



13



27

Golden Rules • OEE is about Machines NOT people • OEE cannot exceed 100% • 85% is World Class - Car Factory • USE OEE to identify & correct Manufacturing • “Weaknesses” • Ask What if…


28

A Data Collection Form PLEASE PRINT ALL ENTRIESCLEARLY - THANK YOU.

Date / Shift

Store/Product

A: Shift Start Time

B: Shift End Time

Event No.

Spare Start Time

DAILY or SHIFT DATA CAPTURE FORM AND OEE CALCULATION Machine:

Operation:

Cell:

* Breaks (45 mins), PM, CI,

D=B-A-C

Minutes/Piece

C: Agree Down Time*

D: Running Time (Mins)

Downtime Type of Loss End Time (code)

Duration

H: Rounds Scrapped

J: Operating Time:

Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.

G: Good RoundsPacked in Shift:

F: Total Duration of Lost Time (mins) D- F

E:Machine Rate:

J divided by D x100

Ex (G+H) divided by J x 100

G divided by (G+H)

Availability :

Performance:

Right First Time

Availability x Performance x Right First Time (As Decimals)

OEE : LOSS CODES A. 'Material & Tool Losses B. Labour Losses

C. 'Planned Losses

Headcount

A 1 1 P a rt s un us ab le A 12 Tooling unusable

C4 1 5 C / 5S A ct iv it e i s C42 Pr oces s / Tool Change Over C43 Cle an down machine Planned Maintenance ActivitieC44 Change process lubric ant D. ' MethodLosses Duplication C21 Scheduled PPMactivities De velopme nt D11 Operatio n repeate d C51 Training

Delivery

A21 Waitingfor material A22 Waitin g for toolin g

CI Activitie s B 11 N oL ab ou r Av a li ab leC1 1 Co nt n i uo us Im pr ov em en t C12 Meeting

E. 'Machine Losses

Supplier Quality

Planned not to run

Bre ak down los se s

Idling & Minor Stoppage s E1 1 S u dd en me ch an ic al f a il ur e * E4 1 B re ak do w n of p r ev io us ma ch in e E12 S udden electric al failure * E42 Breakdow n of subs equent mac hine E13 PLCor software systemfailu re * E43 Component jamming / remove &reset E14 Mis c (please specif y) Start up Losses Se t-up adjustment loss es E61 Machine not stable on start-up E21 Setting / Adjustments



14



29

So let’s work another one through… •

Your shift runs 06:00 to 14:00

•

You have 1 x15 minute break and 1 x 30 minute break during the shift

•

During the shift you had two plant failures of 30 minutes and 45 minutes respectively which stopped production. A Spare had to be fetched for the second repair

•

You produced 2000 items

•

The machine speed is 10 items per minute

•

10 of these were reject, and had to be scrapped (rework would count too not right first time)

•

Please calculate the availability, performance, quality efficiency, and the overall OEE


PLEASE PRINT ALL ENTRIES CLEARLY - THANK YOU.

Date / Shift

Store/Product 19/10/2004

A: Shift Start Time

B: Shift End Time

:

Event No.

Operation: closing D=B-A-C

C: Agree Down Time*

D: Running Time (Mins )

mns


Start Time

Cell:

Our Machine * Breaks (45 mins), PM, CI,

:

Spare

30

DAILY or SHIFT DATA CAPTURE FORM AND OEE CALCULATION Machine:

Rarden case

rs

Duration

mns =

Main manf plant area 5 Minutes/Piece

E:Machine Rate:

mns

. mnu e/ em


1

09:15

09:45

E11

30 mins

jammed cap feeder

2

11:00

11:45

E11

45 mins

jammed cap feeder spare fetched from Fitter's store


H: Rounds Scrapped

10

J: Ope ra ti ng Time :

75 mins

360 mins

Ava ila bility :

2000

G: Good Rounds Packed in Shift:

J divided by D x100

82.70%

E x (G+H) divided by J x 100

G divided by (G+H)

Pe rforma nce :

Right First Time 99.5%

55. 8%


45.90%

OEE : LOSS CODES A. 'Material & Tool Losses B. Labour Los ses Supplie r Quality A 11 Pa rt s un us ab le A12 Tooling unusable Delivery A21 Wait ing for materia l A 2 2 W ai ti ng f o r t oo li ng

C. 'Planned Losses

Headcount CI Activities B 11 No La bo ur A va ila bl C1 1 Co nt in uo us Imp ro ve me nt C12 Meeting

E. 'Machine Losses

Planne d not to run C4 1 5 C/ 5 SA c ti vi ti es C42 Process / Tool Change Over C43 Cle an down machin e Planned Maintenance Activiti C44 Change process u l bric ant D. ' MethodLosses Duplication C21 Scheduled PPMactivities D1 1 O pe ra ti on r e pe at ed Development C51 Training

Bre ak dow n los se s Idling & Minor Stoppages E1 1 S u dd en me ch an c i al f ail ur e * E4 1 B re akd ow n of p re vio us ma ch in e E12 Sudden electrical failure * E42 Breakdow n of subsequent machine E13 PLC or software systemfail ure * E43 Component jammin g / remove & reset E14 Mis c (please specify) Start up Losses Se t-up adjustm ent losse s E61 Machine not stable on start-up E21 Setting / Adjustments



15



Store/Product /

/

Machine: rea s (

B: Shift End Time

:

Event No.

Operation:

ar en case

A: Shift Start Time

mns ,

apper , I,

:

appng

Start Time

rp nu es/ ece

D: Running Time (Mins )

mns


Cell:

= - -

C: Agree Down Time*

Spare

31

DAILY or SHIFT DATA CAPTURE FORM AND OEE CALCULATION


Date / Shift

rs

mns =

E:Machine Rate:

mns

. mnu e/case


Duration

1

09:15

09:45

E11

30 mins

jammed feeder

2

11:00

11:45

E11

45 mins

jammed feeder spare fetched from Fitter's store

435 - 75 = 360mins

75 mins


H: RoundsS crapped

10

J: Ope ra ti ng Ti me :

360 mi ns

Ava il abi li ty :

2000

G: Good RoundsPa cked in Shift:

J divided by D x100


82. 70%

Pe rforma nce :

55. 8%

G divided by (G+H)

Ri ght Fi rst Ti me 99. 5%


45.90%

OEE : LOSS CODES C. 'Planned Losses

A. 'Material & Tool Losses B. Labour Los ses Supplier Quality A 11 Pa rt s un us ab le A12 Tooling unusable

E. 'Machine Losses

Headcount CI Activities B 11 No La bo ur A va ila bl C1 1 Co nt in uo us Imp ro ve me nt C12 Meeting

Delivery A21 Wait ing for materia l A 2 2 W ai ti ng f o r t oo li ng

Planned not to run C4 1 5 C/ 5 SA c ti vi ti es C42 Process / Tool Change Over C43 Cle an down machin e Planned Maintenance Activiti C44 Change process u l bric ant D. ' MethodLosses Duplication C21 Scheduled PPMactivities Development D1 1 O pe ra ti on r e pe at ed C51 Training

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an c i al f ail ur e * E4 1 B re akd ow n of p re vio us ma ch in e E12 Sudden electrical failure * E42 Breakdow n of subsequent machine E13 PLC or software systemfail ure * E43 Component jammin g / remove & reset E14 Mis c (please specify) Start up Losses Set-up adjustment losses E61 Machine not stable on start-up E21 Setting / Adjustments



Date / Shift


B: Shift End Time

06:00

Event No.

Machine:

Rarden case

A: Shift Start Time

Operation:

ADL Capper * Breaks (45 mins), PM, CI,

D=B-A-C


Capping

45mins


Start Time

Cell:

C: Agree Down Time*

14:00

Spare

32

DAILY or SHIFT DATA CAPTURE FORM AND OEE CALCULATION Grp 4 Minutes/Piece

E:Machine Rate:

7hrs 15 mins = 435 mins

Duration

0.1 minute/case


1

09:15

09:45

E11

30 mins

jammed cap feeder

2

11:00

11:45

E11

45 mins


360/435x100 = 82.7% F: Total Duration of Lost Time (mins) D- F

H: Rounds Scrapped

10

J: Ope ra ting Time :

75 mins

360 mins

Ava ila bility :

2000


J divided by D x100

82.70%


G divided by (G+H)

Pe rforma nce :

Right First Ti me 99.5%

55.8%

Availability x Perfor mance x Right First Time (As Decimals)

45.90%

OEE :

A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable Delivery A21 Waiting for material A 2 2 W ai ti ng f or t oo li ng

LOSS CODES C. 'Planned Losses

Headcount CI Activities B 11 No L ab ou r A va li ab l C1 1 Co nt in uo us I mp ro ve me nt C12 Meeting

E. 'Machine Losses

Planned not to run C4 1 5 C/ 5 S A ct iv it e i s C42 Process / Tool Change Over C43 Cle an down machine Planned Maintenance Activiti C44 Change process lubric ant D. ' MethodLosses Duplication C21 Scheduled PPMactivities Development D1 1 O pe ra ti on r ep ea te d C51 Training

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an c i al f ail ur e * E4 1 Br ea kd ow n o f p re vi ou s ma ch n i e E12 Sudden electrical f ailure * E42 Breakdow n of subsequent machine E13 PLC or software systemfailu re * E43 Component jamming / remove & reset E14 Misc (ple ase specif y) Start up Losses Set-up adjustment losses E61 Machine not stable on start-up E21 Setting / Adjustments



16




Date / Shift


B: Shift End Time

06:00

Event No.

Machine:

Rarden case

A: Shift Start Time

Operation:


D=B-A-C


Capping

45mins


Start Time

Cell:

C: Agree Down Time*

14:00

Spare

33

DAILY or SHIFT DATA CAPTURE FORM AND OEE CALCULATION Grp 4 Minutes/Piece

E:Machine Rate:


Duration

0.1 minute/case


1

09:15

09:45

E11

30 mins

jammed cap feeder

2

11:00

11:45

E11

45 mins


0.1x(2000+10)/360 x100 = 55.8%

75 mins


10

H: Rounds Scrapped


360 mi ns

Ava ila bility :

2000


J divided by D x100

82. 70%


G divided by (G+H)

Pe rforma nce :


55.8%

Availab ility x Perfo rmance x Right First Time (As Decimals)

45.90%


A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable

E. 'Machine Losses

Headcount CI Activities B 11 No L ab ou r Av ai a l bl C1 1 Co nt in uo us I mp ro ve me nt C12 Meeting

Planned not to run C4 1 5 C/ 5 S Ac ti vit ie s C42 Process / Tool Change Over C43 Clean down machin e Planned Maintenance ActivitieC44 Change process lubric ant D. ' MethodLosses Duplication C21 Scheduled PPMactivities Development D1 1 O pe ra ti on re pe at ed C51 Training

Delivery A21 Waiting for material A 2 2 W ai ti ng f or to ol n i g

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an ic al f ai u l re * E4 1 B re ak do w n of p re vio us ma ch in e E12 Sudden electrical f ailure * E42 Breakdow n of subsequent machine E13 PLCor software system failu re * E43 Component jamming / remove & reset E14 Mis c (ple ase specif y) Start up Losses Set-up adjustment losses E61 Machine not stable on start-up E21 Setting / Adjustments



Date / Shift

Store/Product /

/

Machine: rea s (

B: Shift End Time

:

Event No.

Operation:

ar en case

A: Shift Start Time

mns ,

apper , I,

:

appng

Start Time

rs

Duration

rp nu es/ ece


mns


Cell:

= - -

C: Agree Down Time*

Spare

34


mns =

E:Machine Rate:

mns

. mnu e/case


1

09:15

09:45

E11

30 mins

jammed cap feeder

2

11:00

11:45

E11

45 mins


2000/(2000+10) x100


H: Rounds Scrapped

10


75 mins

360 mi ns

Ava ila bility :

2000


J divided by D x100

82. 70%


G divided by (G+H)

Pe rforma nce :


55.8%


45.90%

OEE :

A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable Delivery A21 Waiting for material A 2 2 W ai ti ng f or to ol n i g



E. 'Machine Losses





17




Date / Shift 19/10/04

B: Shift End Time

06:00

Event No.

Machine:

Rarden case

A: Shift Start Time

Operation:


D=B-A-C


Capping

45mins


Start Time

Cell:

C: Agree Down Time*

14:00

Spare

35


Store/Product

Grp 4 Minutes/Piece

E:Machine Rate:


Duration

0.1 minute/case


1

09:15

09:45

E11

30 mins

jammed cap feeder

2

11:00

11:45

E11

45 mins


0.827x0.558x0.995x100 =45.9%

75 mins


H: Rounds Scrapped

10


360 mi ns

2000


J divided by D x100

Ava ila bility :

82. 70%


G divided by (G+H)

Pe rforma nce :


55.8%


45.90%


A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable Delivery A21 Waiting for material A 2 2 W ai ti ng f or to ol n i g

E. 'Machine Losses





36

A picture is worth a thousand words Our Plant OEE

Plot The Result on the board supplied

100 80 E E O

OEE

60

Availability

40

Performance

20

Quality

0 0

10

20

30

Day



18



37

Maintain a log sheet to show Whole day break detail

downs: Availability: 0 OEE= 0% Overall Equipment Effeciveness (OEE) Log Sheet (Provided we would have used plant Machine: Month: if it had been up.)

Store/Product: Day

Availability %

Performance %

Right First Time %

OEE %

1 2

0

3

0

4 5 6 7 8 9 10 11


38

Maintain a log sheet to show detail Overall Equipment Effeciveness (OEE) Log Sheet Store/Product: Day

Machine:

Availability %

Performance %

Month:

OEE % When we didn’t use it and we didn’t want to. I.e. Weekends with no O/T planned

Right First Time %

1 2 3 4 5 6 7 8 9

-

-

10 11

To Office at Month End Please to include Average in KPI’s SSG06101ENUK – Delegate Slides/Issue 1.1/ April 2008


19



39

Golden Rule • Cells will be encouraged to ask “What if”…………. • What if we did not have to wait for an Fitter? • What if we did not have to wait for a spare part? • What if we had a breakdown mid morning break and took our break then rather than waiting for the right time? • What if the plant is running and we took a break by splitting the shift? • What if we developed a Capital Case to replace the plant?


40

Let’s try to answer some of these questions • Let’s remove the some of the Unplanned Downtime (waiting for Fitter 15 mins & waiting for spare to be fetched 15 mins, total = 30 mins) • Downtime is reduced to from 75 to 45 mins……… • And if we assume an extra 120 items could be produced increasing our output from 2000 to 2120……………..



20



41



Date / S hift

Store/Product /

/

A: S hift Start Time

B: Shift End Time

06:00

Event No.

Machine:

arden case

Operation: D=B-A-C

C: Agree Down Time*


14:00

appng

45mins


Spare Start Time

Cell:

our pan * Breaks (45 mins), PM, CI,

rp Minutes/Piece

E:Machine Rate:


0.1 minute/case


Duration

1

09:15

09:30

E11

15 mins

jammed feeder

2

11:00

11:30

E11

30 mins


390/435x100 = 89.7% 45 mins


10

H: RoundsS crapped

J: Ope ra ti ng Ti me :

390 m ins

2120

G: Good RoundsP acked in Shift:

J divided by D x100

Ava il abi li ty :

Ex (G+H) divided by J x 100

89 .70%

Pe rfor ma nce :

54. 6%

G divided by (G+H)

Ri ght Fi rst Ti me 99. 5%

Availab ility x Performance x Right First Time ( As Decimals)

48.70%


A. 'Material & Tool Losses B. Labour Losses upp er ua y A 11 Pa r ts u nu sa bl e oo ng unusa e

E. 'Machine Losses

ea coun c v es B 11 N oL ab ou r A v ai la bl eC 11 C on ti nu ou s Imp ro v eme nt ee ng

anne no o run C 41 5 C / 5 S A c ti vi ti es rocess / oo ange ver C43 Cle an down machine an ne a n e na nc e c v e ange pr oc es s u r c an D. ' MethodLosses c e du e d acv es Duplication eve opmen pera on repea ed ranng

e ve ry a ng for maera a n g for oo ng

rea ow n osses ng nor oppages E1 1 S ud de n m ec ha ni c al f a il ur e * E4 1 B re ak do w n o f p re v o i us ma ch in e udden e ec r ca fa ure * rea dow n of su sequen mac ne E13 PLCor software syste mfail ure * E43 Component ja mmin g / remove &reset sc ( pease s pec fy Start up Losses e -up a u s men osses a c n e n o s a e on s a r - up e n g / d u s m en s


42

DAILY or SHIFT DATA CAPTURE FORM AND OEE C ALCULATION


Date / S hift

Store/Product

an

/

/

A: S hift Start Time

B: S hift End Time

06:00

Event No.

Machine:

arden case

Operation: D=B-A-C

C: Agree Down Time*


14:00

app ng

45mins


Spare Start Time

Cell:

our p an * Breaks (45 mins), PM, CI,

p an Minutes/Piece

E:Machine Rate:


Duration

0.1 minute/item


1

09:15

09:30

E11

15 mins

jammed feeder

2

11:00

11:30

E11

30 mins


0.827x0.558x0.995x100 =48.7% F: Total Duration of Lost Time (mins) D- F

H: RoundsScrapped

10

J: Op era ti ng Ti me :

45 mins

39 0 m ins

Ava il abi li ty :

2120

G: Good RoundsPacked in Shift:

J divided by D x100

89. 70 %


G divided by (G+H)

P erfor ma nce :

Ri gh t Fi rst T ime 99. 5%

54. 6%


48.70%

OEE :

A. 'Material & Tool Losses B. Labour Losses upp er ua y A 1 1 Pa r ts u nu sa bl e A12 Tooling unusable Delivery a ng for maera A 2 2 W ai ti ng f or t oo li ng


ea coun c v es B 11 N oL ab ou r A v ai la bl eC1 1 C on ti nu ou s Im pr ov e me nt C12 Meeting

E. 'Machine Losses

anne no o run C 41 5 C / 5 S A c ti vi ti es C42 Process /Tool Change Over ean dow n mac ne Planned Maintenance Activitie C44 Change process lu bricant D. ' MethodLosse s upcaon c e du e d acv es Development D 11 O pe r at io n re pe at ed ranng

rea ow n osses ng nor oppages E1 1 S ud de n me c ha ni ca l f a li ur e * E4 1 B re ak do w n o f p re v o i us ma c hi ne E12 S udden electrical failure * E42 Breakdow n of subsequent mac hine or s of w a re s ys e mf a ure * omponen a mm ng / r emove r es e E14 Mis c (please specify) ar up osses Set-up adjustment losses E61 Machine not stable on start-up e ng / dusmens



21



43

Outcome • We can see an improvement of 7% on Machine Availability and an increase of 2.8% on OEE • These are small theoretical increases, but they cannot be discounted………………………………. • Many small gains all add up


44

More what ifs • The obvious questions arise………………………. • Why can’t we have more fitters? • Why not keep a spare part on the job? • Can we take breaks nearer the job? • Can we have a extra hand at break times to make splitting easier?



22



45

What about a new Machine?


46 PLEASE PRINT ALL ENTRIES CLEARLY - THANK YOU.

Date / Shift


Machine:

Rarden case

A: Shift Start Time

B: Shift End Time

06:00

Event No.


Start Time

Cell:

D=B-A-C

Minutes/Piece


E:Machine Rate:

14:00

Spare

Operation:


C: Agree Down Time*

Capping

45mins


Grp 4


Duration

0.1 minute/case


435/435x100 = 100% F: Total Duration of Lost Time (mins) D- F

H: Rounds Scrapped

10

J: Operating Time:

0 mins

435

Availability :

2750


J divided by D x100

100.00%


G divided by (G+H)

Pe rformance:


63.9%


63.50%

OEE :

A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable Delivery A21 Waiting for material A 2 2 W ai ti ng f or t oo li ng


Headcount CI Activities B 11 No L ab ou r Av ai a l bl C 11 Co nt n i uo us I mp ro ve me nt C12 Meeting

E. 'Machine Losses

Planned not to run C4 1 5 C / 5S A ct iv it e i s C42 Proc ess / Tool Change Ov er ean dow n mac ne Planned Maintenance Activiti C44 Change process lu bricant D. ' MethodLosses Duplication C21 Scheduled PPMact ivities D 11 O pe ra ti on r ep ea te d Development C51 Training

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an ic al f ai u l re * E4 1 B re ak do w n of p r ev io us m ac hi ne E12 Sudden elec tr ic al failure * E42 Breakdow n of subs equent machine or s o w a re s ys e m a u re omponen amm ng / r emov e r es e E14 Mis c (please specify) Start up Losses Set-up adjustment losses E61 Machine not stable on start-up E21 Setting / Adjustments



23




ate

t

tore 19/10/04

ro uct

ac ne:

Rarden case

A: Shift Start Time

B: Shift End Time

06:00

Event No.


Start Time

e :

D=B-A-C

Minutes/Piece

C: Agree Down Time*


E:Machine Rate:

14:00

Spare

perat on:


Capping

45mins


Grp 4


Duration

0.1 minute/case


Record shift

0 mins


H: Rounds Scrapped

10

J: Operating Time:

435

Availability :

2750


J divided by D x100

100.00%


G divided by (G+H)

Pe rformance:


63.9%


63.50%


A. 'Material & Tool Losses B. Labour Losses Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable

E. 'Machine Losses


Delivery A21 Waiting for material A 2 2 W ai ti ng f or t oo li ng

Planned not to run C4 1 5 C / 5S A ct iv it e i s C42 Proc ess / Tool Change Ov er ean dow n mac ne Planned Maintenance Activiti C44 Change process lu bricant D. ' MethodLosses Duplication C21 Scheduled PPMact ivities D 11 O pe ra ti on r ep ea te d Development C51 Training

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an ic al f ai u l re * E4 1 B re ak do w n of p r ev io us m ac hi ne E12 Sudden elec tr ic al failure * E42 Breakdow n of subs equent machine or s o w a re s ys e m a u re omponen amm ng / r emov e r es e E14 Mis c (please specify) Start up Losses Set-up adjustment losses E61 Machine not stable on start-up E21 Setting / Adjustments



Date / Shift



Machine:

Rarden case rea s (

A: Shift Start Time

B: Shift End Time

06:00

Event No.

14:00

Spare Start Time

Operation: ADL Capper mns , , I,

Grp 4 nu es/ ece


45mins


Cell: Capping

= - -

C: Agree Down Time*

E:Machine Rate:


Duration

0.1 minute/case


0.1x(2750+10)/435 x100 = 63.9% F: Total Duration of Lost Time (mins) D- F

H: Rounds Scrapped

10

J: Operating Time:

0 mins

435

Availability :

2750


J divided by D x100

100.00%


G divided by (G+H)

Pe rformance:


63.9%


63.50%

OEE :

A. 'Material & Tool Losses B. Labour Losses


Supplier Quality A 11 Pa rt s un us ab e l A12 Tooling unusable


e v er y A21 Waiting for material a ng or oo ng

D. ' MethodLosses

a nn e a n e n an ce c v up ca o n C21 Scheduled PPMact ivities pera on repea ed

E. 'Machine Losses

Planned not to run C4 1 5 C / 5S A ct iv it e i s C42 Proc ess / Tool Change Ov er C43 Cle an down machine C44 Change process lu bricant eve opmen C51 Training

Breakdown losses Idling & Minor Stoppages E1 1 S u dd en me ch an ic al f ai u l re * E4 1 B re ak do w n of p r ev io us m ac hi ne E12 Sudden elec tr ic al failure * E42 Breakdow n of subs equent machine E13 PLC or software systemfailu re * E43 Component a j mmin g / remove & reset E14 Mis c (please specify) ar up osses e -up a u s men osses a c n e n o s a e on s a r - up E21 Setting / Adjustments



24



49

What about a new machine? • We can see an improvement of 17% on Machine Availability and an increase of 18% on OEE • We would break manufacturing records: 

Allow delivery to customer to promise



make better use of Labour



watching a broken machine has to be unfulfilling as well as a waste

• There would be a payback for the capital investment • First we need some data show how bad things are


50

OEE is: •

A tool for Cells to record and then identify where their Manufacturing weaknesses are, and to rectify these by CI Meetings, seeking assistance from Engineering, QA and Finance or other departments where necessary.



25


10 Overall Equipment Effectiveness

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