OEE Implementation 1 Created By Anang T
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OEE Implementation
Created By Anang T
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Outline : PengenaIan OEE OEE Manufacturing Resep rahasia: I x F x A Studi kasus: OEE Improvement
The Power of OEE
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1. PENGENALAN OEE
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OEE (Overall Equipment Effectiveness) adalah cara "best practice" untuk memonitor dan mengimprove effectiveness dari manufacturing processes (i.e. machines, manufacturing cells, assembly lines).
• OEE adalah metriks terpadu yang mengukur tingkat yang dihasilkan dari suatu proses
Definisi OEE
Masurement adalah dasar dari improvement"
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Body Mass Index Kategori> 30 OBESITAS
25,0 - 29,9 OVERWEIGHT18,5 - 24,9 NOMAL
< 18,5 UNDERWEIGHT
Measurement create Crisis
mass(kg)BMI =
(height(m))2
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Major Losses
Losses Due To Machine
Breakdown
Losses Due To Set Up, Change Over
Losses Due To Deffect
Losses Due To Rework
Speed Loss Minor Stopage
“Berapa Resources Yang Terbuang”
Input : Machine Man
Power Material Energy
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Knowing your Losses is very valuable!
Losses adalah pemakaian resource yang tidak dirasakan oleh end customer tapi hanya menambah biaya produk
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Time Diagram
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Company OEEAwal Untuk OEE Umum 30% - 50%
World Class OEE 85% - 95%
World Class OEE
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OEE = Availability x Performance x QualityOEE Formula
OEE
Availability
Performance
Quality
Breakdown Losses
Minor Stoppage Scrap/Rework
Setup & Adjustment Speed Losses Start Up Six Big Losses
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2. OEE Manufacturing
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OEE & Lean ManufacturingBusiness Result
Return Of Stageholder EquityOperating Margin, Cash Flow
Operating Excellence
Continous Improvement
OEE – Operational Stability5R Stadndart Work, Maintenant Management
People Lean Processes
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Six Big Losses
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Model OEE OEE = Availability x Performance x Quality
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Perusahaan ManufacturingRunning Time = 8 JamBeakdown Mesin = 60 menitSetup Adjustment = 30 menit
Availability = (Actual Running Time / Planed Running Time) x 100%
= (8 Jam – (60+30 Menit) / (8 Jam)) x 100%
= 81 %
Contoh : Availability Calculation
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Avaiability Time = 8 Jam – 1,5 Jam = 6,5 JamTheoritical Speed = 120 Pcs / Jam Actual Output = 580 Pcs (Good+Reject)
Performance = (Actual Output/Theoritical OutPut) x 100%
= (580 Pcs/(120 Pcs/Jam x 6,5 Jam)) x 100%
= 74%
Contoh : Performance Calculation
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Actual Output = 580 Pcs (Good+Reject)Good = 500 PcsReject/Rework = 80 Pcs
Quality = (Actual Good / Actual Output) x 100%
= (500 Pcs/580 Pcs) x 100%
= 86%
Contoh : Quality Calculation
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Availability = 81%Performance = 74%Quality = 86%
OEE = Availability x Performance x Quality
= 81% x 745 x 86%
= 52%
Contoh : OEE Calculation
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3. Latihan Menghitung OEE
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Latihan Menghitung OEE
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Diketahui :
Total Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Theoritical Speed =2.000 Botol/Jam Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol
Hitung : Availability, Performance, Quality dan OEE ?
Hitung OEE Manufacturing
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Availability : (7 x 60) – (45 x 2) / (7 x 60) : 330 / 420 : 78,57 %
Performance : 6.300 / ((330/60) x 2.000): 6.300 / 11.000: 57,27 %
Quality : 5.900 / 6.300: 93,65 %
OEE : 78,57 % x 57,27 % x 93,65 % : 42,14 %
Jawaban Soal :1
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Diketahui : Running Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Cleaning Mesin = 20 Menit Theoritical Speed =2.000 Botol/Jam Idle menunggu Kemasan = 15 Menit Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol Jumlah Yang Bisa di Rework = 200 Botol
Hitung : Availability, Performance, Quality dan OEE ?
Hitung OEE Manufacturing
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How To Improve OEE
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Improve OEEInformation x Focus x Action
Result = I x F x A Terlalu Banyak Data, Tetapi Tidak Banyak Informasi
Tidak ada Informasi Dapat Berarti Keputusan dibuat Berdasarkan Insting. Ketiadaan Informasi menyebabkan tidak ada focus di perusahaan
Tidak ada Fokus utama untuk Improvment.effisiensi hanya menjadi sakah satu performance Indikator, tetapi belum menjadi sasaran satu perusahaan.
Tidak ada nya fokus menjadi penyebab tidak adanya alasan nyata untuk aksi.
Tidak ada aksi untuk mencapai sasaran bersama. Semua menjalankan bisnis as ussual (seperti biasanya)
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Accurate Data As Close to real time as you can get it Focusing On what caused you to be off track Review regularly and act !!!
Informasi Yang Tepat
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Collect Data pada banyak mesin, masalah produkstivitas,Tidak ada waktu - terlalu sibuk
Data tidak akurat :Tidak merekan minor StopMembulatkan angkaBudget Time
Karena data idak akurat, maka data tidak dipakai, sehingga operator tidak mengisi dengan benar.
Hasilnya : Tidak ada improvement
Issue menggunakan manual data collection
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Keuntungan Automated Data Collection
Manual System - Reaktif Automated System - Proaktif
Slow Reaktion Rapid Reaction
Historical Information Real Time
Snap Shot Audit Continous Visualization
Inaccurate data Accurate DataPerceived Losses On Critical Machine Real Losses on Critical Machine
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OEE Score Board (OEE DashBoard)
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