Production Line OEE (Overall Equipment Effectiveness)

Improving Plant Performance

Lonnie A. Bowling and Read Hayward

DST Controls

February 24, 2016

Overall Equipment Effectiveness

“It measures the gap between actual performance verses potential performance

for a manufacturing unit”

Why this really matters

• 10%-50% improvement in performance• Where to spend money for improvements?• Do improvements deliver the expected results?• Determining where and why performance is lost

OEE – Overall Equipment Effectiveness

OEE = Availability X Performance X Quality

Availability = 77% Performance = 95% Quality = 92%

77% x 95% x 92%

OEE a bit deeper

1. Schedule Time – when should we be running

2. Operating Time – when did we actually run

3. Ideal Cycle Time – calculated time to make a part

4. Parts Produced – actual parts produced

5. Good Parts Count – good parts produced

OEE a bit deeperAvailability = Operating Time / Schedule TimePerformance = Parts Produced / (Operating Time / Ideal Cycle Time)Quality = Good Parts Count / Parts ProducedOEE = Availability x Performance x Quality

Availability 72% x Performance 84% x Quality 78%

Getting Started – Automate Data Collection

1. Schedule Time – a set schedule and adjustments

2. Operating Time – start/stop of the machine/line

3. Ideal Cycle Time – a simple value that never changes

4. Parts Produced – sensor to count parts

5. Good Parts Count – sensor to count good or bad parts

Check List: Things that you need

1. OEE Software – like FactoryTalk Metrics2. A Server that can run the software3. A PLC that can monitor the equipment4. A network for communications5. DST to get you going!

Where can this lead?

Business Drivers:• Determining where bottlenecks occur (due to frequent process

improvements)• Performance reporting in real-time• Frequent inventory adjustment

Barry Callebaut Case Study

SolutionAutomated collection of OEE and Production Data

SolutionEvent Data to Support Process Improvements

SolutionMonitoring Case Weights

SolutionReal-Time OEE Reporting

What was Achieved

• $400,000 savings in 5 months• Better control of inventory and quality adjustments• Cost impact of changes visible instantly• Real-time reports• Validating improvements

Summary

• OEE measures the overall performance gap• OEE can start simple• Monitoring performance is critical• Automated data collection and real-time reporting is key• DST is here to help!

About DST Controls

• Located in SF Bay Area, Benicia CA• 40 Employees, 3 Divisions – Manufacturing, Controls, Data• Information Focused – Collection, Analytics, Visualization• Industrial IT Services Specialization• Rockwell Recognized Partner• Microsoft Silver Partner• CISCO Certification in Progress

Lonnie A. Bowling

• [email protected]• Business Development Director• (707) 637-3298

Read Hayward

• [email protected]• Vice President• (707) 748-5519

DST Controls Thanks You!