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*OVERALL EQUIPMENT EFFECTIVENESS (O E E)A practical approach to
problem solving & increasing Maintenance CircleClick mouse or
any key to continue
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*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 Maintenance Circle
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*What is O E E ?Overall Equipment Effectiveness is a measure of
equipments NETT efficiency taking into account, following six major
losses, advocatedin TPM
BREAKDOWN LOSSESSET UP & ADJUSTMENT LOSSESIDLING & MINOR
STOPPAGESSPEED LOSSESREDUCED YIELDQUALITY REWORK /
REJECTSMaintenance Circle
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*BREAKDOWN LOSSESSporadic stoppage of machineUn-noticed failure
of certain componentsAccelerated deterioration of
equipmentRepetition of certain problems, during productionMajor
downtimes affecting productionFunction loss & Function
reductionMaintenance Circle
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*SET UP & ADJUSTMENT LOSSESRepeated adjustments of process
parameters during productionNon-standard approach to tool / process
settingFrequent order changes on a machineRepetition of certain
problems, during productionMajor downtimes affecting
productionMaintenance Circle
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*IDLING & MINOR STOPPAGESRepeated jams / sensor failures /
robot malfunctionsShortage of supporting materials: packing
material, palettes, trolleys to name a fewNo fault indication, when
machine stops leading to confusionMachine running without actual
output (idling)Shift change-overMaintenance Circle
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*SPEED LOSSESMachine running slower than designed or desired
speedProcess slowing down due to downstream limitationsMachines
inability to withstand the designed or desired speedPast
experienceFear of producing rejectionsMaintenance Circle
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*REDUCED YIELDToo many stops & starts resulting in reduced
stabilization periodProcess limiting ramp-up & ramp-down time,
reducing outputUp stream or down stream process limiting the
ramp-up & ramp down periods.Maintenance Circle
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*QUALITY REWORK & REJECTSDuring every start-up (and
sometimes, during stopping also), machine produces rejectionEnd
product rejected due to various reasonsRejection at customers site
due to various reasonsMeasuring system not consistent with process
resulting in increased sampling quantitiesToo many reworks before
finishing the productMaintenance Circle
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How to calculate O E E ?*Maintenance CircleOpen 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 applicationsCertain 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.
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How to achieve higher O E E ?Start recording all the relevant
data from production:Planned hoursActual run hoursMachine
breakdownStoppages due to material, pallet change, shift change
etc.Quantity rejected in process, in inspection, at dispatch and
possibly from customers endDivide the data into various segments of
Production, Maintenance & QualityStart measuring O E E for 4 to
6 weeks continuously and study the weak linksCreate small teams to
work on individual weak links that contribute to O E E Fine tune
the data / targets from time-to-time*Maintenance Circle
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*Hidden benefits of O E E Increase in productivity without huge
monetary investment; of course time and people will be involvedAll
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 lineReduced
customer complaintsReduced breakdowns in machineLast but not least,
it saves power to the organization, since machines are run
efficientlyMaintenance Circle
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Thank You*Maintenance Circle
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