Click mouse or any key to continue

OVERALL EQUIPMENT
EFFECTIVENESS (O E E)
A practical approach to problem
solving & increasing

Monday, June 15, 2015

Maintenance Circle

HOW IS YOUR MACHINES MEASURED ?

PROCESSED OUTPUT / PLANNED OUTPUT ?

ACHIEVED HOURS / PLANNED HOURS ?

ACTUAL DELIVERY / PLANNED DELIVERY ?

QUANTITY ACCEPTED / (QUANTITY ACCEPTED + QUANTITY REJECTED ) ?

Any other method...

Over last 3 months, was your machine more than 85% ?

Over last 3 months, was your machine downtime less than 3% ?

Are your customers happy with your product & delivery ?

If your answer is YES or NO to above questions, its time to measure O E E

Monday, June 15, 2015

Maintenance Circle

What is O E E ?

Overall Equipment Effectiveness is a measure of equipments NETT

efficiency taking into account, following six major losses, advocated
in TPM
BREAKDOWN LOSSES
SET UP & ADJUSTMENT LOSSES
IDLING & MINOR STOPPAGES
SPEED LOSSES
REDUCED YIELD
QUALITY REWORK / REJECTS

Monday, June 15, 2015

Maintenance Circle

BREAKDOWN LOSSES
Sporadic stoppage of machine
Un-noticed failure of certain components
Accelerated deterioration of equipment
Repetition of certain problems, during production
Major downtimes affecting production
Function loss & Function reduction

Monday, June 15, 2015

Maintenance Circle

SET UP & ADJUSTMENT LOSSES

Repeated adjustments of process parameters during production
Non-standard approach to tool / process setting
Frequent order changes on a machine
Repetition of certain problems, during production
Major downtimes affecting production

Monday, June 15, 2015

Maintenance Circle

IDLING & MINOR STOPPAGES

Repeated jams / sensor failures / robot malfunctions
Shortage of supporting materials: packing material, palettes,
trolleys to name a few
No fault indication, when machine stops leading to confusion
Machine running without actual output (idling)
Shift change-over

Monday, June 15, 2015

Maintenance Circle

SPEED LOSSES
Machine running slower than designed or desired speed
Process slowing down due to downstream limitations
Machines inability to withstand the designed or desired speed
Past experience
Fear of producing rejections

Monday, June 15, 2015

Maintenance Circle

REDUCED YIELD
Too many stops & starts resulting in reduced stabilization period
Process limiting ramp-up & ramp-down time, reducing output
Up stream or down stream process limiting the ramp-up & ramp
down periods.

Monday, June 15, 2015

Maintenance Circle

QUALITY REWORK & REJECTS

During every start-up (and sometimes, during stopping also),
machine produces rejection
End product rejected due to various reasons
Rejection at customers site due to various reasons
Measuring system not consistent with process resulting in
increased sampling quantities
Too many reworks before finishing the product

Monday, June 15, 2015

Maintenance Circle

How to calculate O E E ?
Open the attached excel-sheet object to
calculate & understand O E E for two
applications. Of course, once you understand
the concept, it can be calculated to almost all
applications
Certain parameters need to be measured and recorded
for correctly calculating OEE. The measures could be
obtained
from
production
records,
measuring
instruments, machine control system. Correct
parameters must be decided upon to calculate realistic
OEE.
Monday, June 15, 2015

Maintenance Circle

How to achieve higher O E E ?

Start recording all the relevant data from production:
Planned hours
Actual run hours
Machine breakdown
Stoppages due to material, pallet change, shift change etc.
Quantity rejected in process, in inspection, at dispatch and
possibly from customers end
Divide the data into various segments of Production,
Maintenance & Quality
Start measuring O E E for 4 to 6 weeks continuously and study
the weak links
Create small teams to work on individual weak links that
contribute to O E E
Fine tune the data / targets from time-to-time
Monday, June 15, 2015

Maintenance Circle

Hidden benefits of O E E
Increase in productivity without huge monetary investment; of
course time and people will be involved
All hidden losses will be made visible ensuring better clarity
Increase in profit margin of the company: Remember, O E E is
one of the best methods of achieving profits without hurting the
bottom line
Reduced customer complaints
Reduced breakdowns in machine
Last but not least, it saves power to the organization, since
machines are run efficiently

Monday, June 15, 2015

Maintenance Circle

Thank
You
Monday, June 15, 2015

Maintenance Circle