Basics of OEE Loss Tree

Why Effective Maintenance?

100%

Do you think this

is true?

90%
80%

Equipment
q p
Breakdown
5.57%

70%
60%

AAMET Loss Structure

50%
40%

Minor Stoppages
5.21%

30%
20%
10%
0%

Changeovers
2.02%
Asia/AMET Total

Equipment Breakdown

5.57

Minor Stoppages

5.21

Changeovers

2.02

A
C
M

Priority to be solved

Dies Temperature
Wrapping

ur

22%

ra
t

14%

Te
m
pe

7%

Sy
st
e

0%

EQ
.B
R

EA

D
J

O
W

20%

K
D

PP
A
G

IC

O
R
K

O
VE
R

LO
G
IS
T

R
EW

N
G
E

ST
O

&

C
T

M
IN
O

EF
E

SE
R
VI
C

&

14%

ra
pp
in
g

52% 20%

ol

C
H

U
P

40%

D
ie
s

19%

9%

on
tr

29%
U

R
EM
EN

R
T

20%

48%

4%

Pa
pe
r

60%

Su
ct
io
n

60%

120%

SU

ST
A

2%

80%

100%
100%
80%

Breakdown
R
EL
IG
IO

M
EA

0%

O
th
er

em

ur
e

40%

Sy
st

ra
t

100%

pi
ng

pe

22%

W
ra
p

Su
ct
io
n

16%

Te

ro
l

10%

C
M

rC
on
t

ill

6%

st
em

3%

O
th
er

Sy

em

0%

pe

in
g

Sy
st

20%

Pa

ea
t

ol

100%

on
tr
120%

D
ie
s

16 Big Losses
120%

Lost Tree
100%

80%

60%
62%

41%

22%
21%
38%

Minor Stoppages
100%

56%

40%

34%
44%

16 Big Losses in Manufacturing

5 Major Manpower Losses
(accompany the 7 major losses in equipment)

Awaiting
materials
loss
(9) Management
L
Loss

(10) Operating Motion

Loss
Equipment Downtime loss
Equipment Performance loss
Method/Procedures loss
Skill & moral loss

(11) Line Organisation

Loss

Operating man hour

Loading man hour
Net Operating
man hour
Effective
man hour
Valued
man hour

7 Major Losses which obstruct Overall Equipment Efficiency (OEE)

Working hour
Loading Time
Operating Time
Net
Operating Time
Valued
Operating Time

3 Major Losses which obstruct Efficiency of

material,die,jig,tool and energy

(15) Energy Loss

Scheduled downtim
me

Awaiting
Instruction
loss

(14) Yield Loss

Line Organisation loss

Start-up loss

Automatization failure loss

Defects quality loss

Start-up loss

Overload loss

(12) Logistics

Temperature

Cutting loss
Losses in weight
Losses in overages

Downtime Loss

Performance Loss

Defects
Quality
Loss

(8) Shutdown
Sh td
L
Losses

(1) Equipment Failure

Loss

(2) Set-up
S t
and
d
Adjustment Loss

(3) Cutting blade and

jig change Loss

(4) Start-up Loss

(16) Die, tool & jig Loss

Awaiting
Instruction
Awaiting
materials

Other downtime Loss

(5) Minor Stoppages

& idling Loss

(6) Speed Loss

(7) Defects
& Rework Loss
(13) Measurement &
Adjustment loss

Cleaning
checking

Awaiting
personnel
distribution
Quality
confirmation
(adjustment of
measurement)

Semua Losses - > Biaya

1

Equipment Breakdown

p Change
g Over
Set Up/

3
7 Major Equipment Losses

4
5
6
7

Shutdown Loss

5 Major Manpower Losses

Minor Stoppage
Speed
Defects and Rework

M
Management
t

10

Operational Motion

11

Line Organisation

14

Losses

Start Up / Ramp Down

Shutdown

13

3 Major
j Material & Energy
gy

Aktivitas Rutin

12

15
16

T
o
t
a
l

T C
i o L
m s o
e t s
s
e
s

L i ti
Logistics
Measurement & Adjustment
Energy
Maintenance Spare Parts
Yield

C
o
s
t

C
o
s
t

7 losses Penghambat OEE

100%

Aktivitas Rutin

Speed Loss

Capability

Aktivitas Rutin

Time

Start-Up

Minor Stoppages

Defects

Failures/
Breakdown

Setup &
Adjustment
(C/O)

Ramp-Down

1. Failure Loss (Breakdown)

Ini adalah loss karena mesin berhenti (tidak diharapkan) yang

sama atau lebih dari 10 menit, dan terjadi secara sporadik
ataupun kronis (dalam periode 1 shift)
shift).
Contohnya :
1 Motor
1.
M t terbakar
t b k
2. Shaft patah
3. Bearing
g Macet
Note : Jika kerusakan berlangsung ke shift berikutnya (misalnya karena
p
p
part, maka shift berikutnya
y akan dihitung
g sebagai
g PM))
tidak ada spare

Failure Loss (Breakdown)

100% Capability

Time
Failures

2. Set-up / Change Over Loss

Total waktu yang diperlukan untuk melakukan Change Over

dari produk 1 ( pada speed dan kualitas normal ) ke produk
lainnya ( pada kecepatan dan kualitas normal ).
L
Loss
iinii ttermasuk
k Ch
Change O
Over P
Packaging,Size,
k i Si
&V
Variant.
i t
Elemen yang paling lama ketika melakukan Change Over
adalah test-running dan adjusment ( penyetelan ).

Set-up / Change Over Loss

100% Capability

Time
Failures

Setup / Change
Over

3. Routine Activity (Aktivitas Rutin) Loss

Loss yang terjadi

L
j di akibat
kib pemberhentian
b h i mesin
i rutin
i untuk
k
mengganti mata gerinda, mata gergaji, cutter ketika sudah
tumpul
p atau rusak ((change
g blade).
)
Loss ini juga termasuk penggantian wrapper, cleaning rutin di
pertengahan minggu (misalnya tiap shift), dll.

Routine Activity Loss

100% Capability
Aktivitas Rutin

Aktivitas Rutin

Time
Failures

Setup & C/O

4. Start Up/Ramp Down Loss

Loss
L
ossyang
yangterjadi
terjadi k
ketika
etikam
memulai
emulai p
produksi.
roduksi L
Loss
ossini
ini d
dihitung
ihitung
mulai dari mesin dijalankan sampai mencapai kondisi stabil
pada kecepatan normal dan kualitas produk yang bagus.

Start Up Losses dapat terjadi setelah :

- Perbaikan rutin (PM)
- Mesin berhenti dalam waktu yyang
g lama
- Liburan
- Istirahat makan

Start Up/Ramp Down Loss

100% Capability
Aktivitas Rutin

Aktivitas Rutin

Time
Start-Up
Loss

Failures

Setup & C/O

Ramp-down
Loss

5. Minor Stoppages & Idling Loss

Berbeda dengan failures/breakdown,

failures/breakdown minor stops
mengakibatkan mesin berhenti sesaat dan jalan lagi dalam
waktu yang relatif singkat ( kurang dari 10 menit ).
H l ini
Hal
i i biasanya
bi
t j di karena
terjadi
k
produk
d k tersangkut
t
k t pada
d suatu
t
bagian mesin atau ketika produk defect mengaktifkan sensor
yyang
g menghentikan
g
mesin.
Pada kasus-kasus ini, produk hanya perlu dipindahkan dan
mesin di-reset untuk dijalankan kembali.

Minor Stoppages & Idling Loss

100% Capability
Aktivitas Rutin

Aktivitas Rutin

Time
Start-Up
Loss

Minor Stoppages
and Idling

Failures

Setup & C/O

Ramp-down
Loss

6. Speed Loss

Loss ini terjadi

j
karena p
perbedaan speed
p
antara design
g speed
p
mesin terhadap speed aktual mesin ketika jalan.
Ketika mesin dijalankan pada design speed, kadang-kadang
mesin bermasalah atau timbul defect pada produk,
produk sehingga
operator menurunkan speed mesin.

Ada 2 tipe Speed Loss :

- Loss karena perbedaan antara actual speed dengan standard speed.
- Loss yang diakibatkan karena design speed lebih rendah dari teknologi
saat ini ataupun kondisi yang diinginkan.

Speed Loss
100% Capability
Aktivitas Rutin

Speed Loss

Aktivitas Rutin

Time
Start-Up
Loss

Minor Stoppages
and Idling

Failures

Setup & C/O

Ramp-down
Loss

7. Defect and Rework Loss

Waktu yang digunakan untuk menghasilkan produk yang reject

dan juga waktu yang digunakan untuk menghasilkan
waste/rework.
as e/ e o

Material/energi yang berkaitan dengan rework ini akan dihitung

pada Energy & Yield Loss.

Defect and Rework Loss

100% Capability
Speed Loss

Aktivitas Rutin

Aktivitas Rutin

Time
Start-Up
Loss

Minor Stoppages
and Idling

Defects

Failures

Setup &C/O

Ramp-down
Loss

Loss mempengaruhi Utilisasi

8. SHUTDOWN LOSS adalah loss akibat scheduled downtime
(planned stoppages). Ini adalah waktu yang yang dijatah tidak
digunakan untuk produksi.
produksi Pengurangan waktu ini adalah
tanggung jawab management atau engineering, bukan
departemen produksi.
Loss ini termasuk :
- Holidays (hari libur)
- No
N P
Production
d ti O
Orders
d
(tid
(tidak
k ada
d rencana produksi)
d k i) misalnya
i l
kkarena :
planner tidak membuat planning, training, teambuilding, dan 3 masalah yang
diketahui 1 shift sebelumnya yaitu tidak ada operator, tidak ada utility, & tidak ada
material.
- Planned Modifikasi
- Planned Maintenance ( PM), termasuk kerusakan mesin/perbaikan (yang
diketahui 1 shift sebelumnya), tidak ada spare part (yang diketahui 1 shift
sebel mn a)
sebelumnya).
- Planned Trial (trial dev (produk, packaging), trial engineering)
- Sholat Jumat

5 Loss impeding Labor Effectiveness

9. MANAGEMENT LOSS
These are waiting time losses generated by management
problems, such as failure to provide materials, spare parts,
utilities, waiting instructions, etc
10. OPERATIONAL MOTION LOSS
This include losses created as a result of difference in skill
levels and losses attributable to inefficient layout, e.g.
walking loss
11 LINE ORGANIZATION LOSS
11.
Loss resulting from the shortage of Operators on the line,
e g meal-break
e.g.
meal break and having to work on more equipment
than was originally planned while he dont have necessary
skills to operate multi lines

5 Loss impeding Labor Effectiveness

12. LOGISTIC LOSS

Time wasted in inefficient delivery of raw, packing,
products, etc to the line and removal of finished products
from the line.
13. MEASUREMENT & ADJUSTMENT LOSS
These are worker-hour losses that result from frequent
implementation of measuring and adjustment to prevent
occurrence off quality
lit d
defects
f t and
d flflow out.
t

3 Loss impeding Resource Cons.

14. ENERGY LOSS
Is the input energy which can not be used effectively for
processing, e.g. start up loss, idling loss.
15. DIE, JIG AND TOOL LOSS
These are monetary losses resulting from the
manufacturing and repair of dies, jigs and tools necessary
for the productions of products
products, as well as the cost of other
supplementary supplies such as cutting & grinding fluid
16. YIELD LOSS
Is the difference between the weight of material fed into
process and the weight of acceptable product
product. It include
material losses in the form of defective product, give away,
over pack, leaks, spills, evaporation, etc

OEE Concept

Mengukur performa lines berdasar tiga

kategori dan 16 loss yang didefinisikan oleh
TPM

OEE = Availability x Performance x Quality

OEE Concept ( contd )

Secara sederhana

OEE = Actual output/ Standard Output

Machine dengan sign off speed 100 ppm

berproduksi 1 shift
f ( 8 jam ),
) machine lancar
dengan out put 25000 product.

Perhitungan :
OEE = 2
25000/(100*480)x100%
000/(100*480) 100% = 52%
2%

OEE & CU
Capacity Utilisation = Loading Time x 100 (%)
Total Time

CU

OEE

Notes:
Standard Cycle Time is based on Line Design speed
Defects include waste and reworked units

Link between Losses & Reasons

4Losses

4Net
4Operating

4Operating
4Time
414

4Losses

4Losses

4Value

4Defects

4Time

4Losses

Time
4Performance

4Operating

Time
4Downtime

4Loading

Shutdown
Los
sses

48-

- Energy
415 - Maintenance spare parts
416 - Yield

Level

Shutdown

41-

Equipment Breakdown
42- Changeover
g
43- Cutting Blade Change
44- Start-up / Ramp down
49- Management
410- Operational Motion
45-

Minor Stoppages
46- Speed
411- Line Organisation
41212 Logistics
47- Defects and rework
413 Measurement &

Adjustment

4Reasons

Level (Some Examples)

4Holidays / Weekends /
4No production orders
4Planned
4Planned

Factory Shutdown

Maintenance
Modification

4Breakdown (>10)
4Changeover - product
4Changeover - format
4Shutdown of the Packing

Line

4If applicable
li bl
4Start up of the Packing Line
4Failure to provide material
4Utilities Stops due the sites reasons
4Power Cuts from Government
4If applicable
4Minor

Stoppages (<10)

4Should

be calculated automatically
4Meals break & Prayer Breaks
4Unexpected lack of operators
4Lack of material at the line
4Lack of product from the process area
4Quality

problem with product

problem with Packaging
4Cleaning routine
4Unexpected 4Sanitisation
4Machine Adjustment
4Quality

Contoh 2

Packaging Machine standard speed 100 ppm

berproduksi selama 1 shift atau 8 hr

Operator melakukan change over product

selama 1 jam

Terjadi beberapa minor stop

Output pada akhir shift 36

36.000
000 product

Hitunglah OEE-nya

Jawaban contoh 2

Availability = ( 8-1)/8*100%=87,5%

Performance = 36000/(100*60*7)=85,7%

Quality = 100%

OEE = 74,98%