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KAILAS SREE CHANDRAN

CLASS: 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.
6  Biggest of SIX BIG LOSSES.
 Tooling Failures
 Unplanned Maintenance
 General Breakdowns
 Equipment Failure
  The time lost due to adjustments
in the equipment.
7  Loss is less then 10 minutes.
 Setup/ Changeover
 Material Shortages
 Major Adjustments
  Small stops losses occur when equipment
stops for a short time as a result of a
temporary problem.
8  These includes stops that are under ten
minutes.
 Component Jams
 Misfeeds
 Sensor Blocked
 Delivery Blocked
 Cleaning/ Checking
  Reduced speed refers to the
difference between Design speed
and Actual Operating speed.
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 Under Nameplate Capacity
 Under Design Capacity
 Due to Equipment Wear
 Due to Operator Inefficiency
  Some equipments require warm-
up time and certain adjustments
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to obtain optimum output.
Startup rejection occurs during
this startup time.
 Scrap
 Rework
  These losses occurs when products
produced are not conforming to the
specifications.
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 These are rejects during steady-state
production.
 Scrap
 Rework
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  The amount of time the facility is open and
available for operation.
13  One year consists of 365 days, one day
consists of 24 hours, 60 minutes in one
hour, 60 seconds in one minute.
 PLANT OPERATING TIME = Fully
Productive Time + Quality Loss + Speed
Loss + Downtime Loss + Planned
Shutdown
 PLANT OPERATING TIME
14 PLANNED
PLANNED PRODUCTION TIME SHUTDOWN

DOWNTIME
OPERATING TIME LOSS

SPEED
NET OPERATING TIME LOSS

QUALITY
FULLY PRODUCTIVE TIME
LOSS
 OEE FACTORS

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  Availability represents the percentage
of scheduled time that the equipment is
16 available to operate.
 Availability takes into account Down
Time Losses.

AVAILABILITY = Operating Time

Planned Production Time
  Performance represents the speed at
which the equipment runs as a
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percentage of its designed speed.
 Performance takes into account Speed
loss.

PERFORMANCE = Net Operating Time

Operating Time
  Quality represents the Good units
produced as a percentage of the Total
18 units produced.

QUALITY = Fully Productive Time

Net Operating Time
 PERFORMANCE AVAILABILITY=
=Actual Run Operating time/
Rate/ Ideal Run Planned
Rate Production Time

19 QUALITY=
Good Pieces/
Total Pieces
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 OEE= AVAILABILITY X PERFORMANCE X QUALITY

23 Availability = Operating Time / Planned Production

Time

Performance = (Total Pieces / Operating Time) / Ideal

Run Rate

Quality = Good Pieces / Total Pieces

  This method use computers for
accessing inputs, calculating OEE
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and its analysis.
 E.g.: OEE IMPACT, VISUAL OEE,
OEE TOOLKIT, PROVIDEAM etc.
 Spreadsheets
 System Software
 o Shift Length: 8 Hours
o Tea Breaks: 10 Minutes x 2
25
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
 OEE= Availability x Performance x Quality
Availability = Operating Time/ Planned
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Production Time
Planned Production Time = Plant Operating
Time – Planned Shutdown
Plant Operating Time= 8 hours x 60 = 480 min.
Planned Shut down = Tea break + Lunch
Break = (10x2) + 60 = 80minutes.
 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)/
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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%
 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
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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%

World
OEE Factor OEE%
Class OEE

Availability 90.00% 88.00%

Performance 95.00% 90.91%
Quality 99.90% 96.75%
Overall OEE 85.00% 77.40%
  World class OEE is a standard which is used to
compare the OEE of the firm.
29 OEE Factor WORLD CLASS
Availability 90%

Performance 95%

Quality 99%
Overall Equipment
85%
Effectiveness
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 PLANT OPERATING TIME
PLANNED
PLANNED PRODUCTION TIME SHUTDOWN
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DOWNTIME
OPERATING TIME LOSS

STOPTIME
RUNNING TIME LOSS

SPEED
NET OPERATING TIME LOSS

FULLY PRODUCTIVE QUALITY

TIME LOSS
  Usability takes into account Stop Time
Loss.
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USABILITY = Running Time

Operating Time
 OEE
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Availability Usability Performance Quality

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 o Shift Length: 8 Hours Downtime
Loss of 48
o Tea Breaks: 10 Minutes x 2 minutes (10%
of Shift)
o Meals Break: 1 Hour
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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
 Availability = Operating Time/ Planned
Production Time
Planned Production Time = 400 minutes
Operating Time = Planned Production Time-
Breakdowns = 400-28 = 372 minutes.
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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
 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
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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 of
OEE and impact of six big losses’, Int. J.
Process Management and Benchmarking,
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Vol.2, No. 3, 2008, pp 234-248.
 Ravikumar M. M., ‘Improving Equipment
Effectiveness’, Int. Business Management,
Vol. 3, No.2, 2008, pp 91-96.
 www.bestmanagementarticles.com
 www.maintenanceworld.com