OEE CALCULATION PPT

OEE Related all details available

1. WELCOME

2. KAILAS SREE CHANDRAN
CLASS: S7 INDUSTRIAL 432
Guide: V REGIKUMAR
OVERALL EQUIPMENT EFFECTIVENESS
OEE

3. MODERN APPROACH TO
OVERALL EQUIPMENT EFFECTIVENESS
OEE

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8. Lossduetobreakdownofequipment.
Lossismorethan10minutes.
BiggestofSIXBIGLOSSES.
ToolingFailures
UnplannedMaintenance
GeneralBreakdowns
EquipmentFailure
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9. Thetimelostduetoadjustments
intheequipment.
Lossislessthen10minutes.
Setup/Changeover
MaterialShortages
MajorAdjustments
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10. Smallstopslossesoccurwhenequipment
stopsforashorttimeasaresultofa
temporaryproblem.
Theseincludesstopsthatareunderten
minutes.
ComponentJams
Misfeeds
SensorBlocked
DeliveryBlocked
Cleaning/Checking
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11. Reducedspeedreferstothe
differencebetweenDesignspeed
andActualOperatingspeed.
UnderNameplateCapacity
UnderDesignCapacity
DuetoEquipmentWear
DuetoOperatorInefficiency
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12. Someequipmentsrequirewarm-
uptimeandcertainadjustments
toobtainoptimumoutput.
Startuprejectionoccursduring
thisstartuptime.
Scrap
Rework
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13. Theselossesoccurswhenproducts
producedarenotconformingtothe
specifications.
Thesearerejectsduringsteady-state
production.
Scrap
Rework
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15. Theamountoftimethefacilityisopenand
availableforoperation.
Oneyearconsistsof365days,oneday
consistsof24hours,60minutesinone
hour,60secondsinoneminute.
PLANTOPERATINGTIME=Fully
ProductiveTime+QualityLoss+Speed
Loss+DowntimeLoss+Planned
Shutdown
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16. PLANT OPERATINGTIME
PLANNED PRODUCTION TIME
PLANNED
SHUTDOWN
OPERATING TIME
DOWNTIME
LOSS
NET OPERATING TIME
SPEED
LOSS
FULLY PRODUCTIVE TIME
QUALITY
LOSS
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17. OEE FACTORS
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18. Availabilityrepresentsthepercentage
ofscheduledtimethattheequipmentis
availabletooperate.
AvailabilitytakesintoaccountDown
TimeLosses.
AVAILABILITY= OperatingTime
PlannedProductionTime
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19. Performancerepresentsthespeedat
whichtheequipmentrunsasa
percentageofitsdesignedspeed.
PerformancetakesintoaccountSpeed
loss.
PERFORMANCE=NetOperatingTime
OperatingTime
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20. QualityrepresentstheGoodunits
producedasapercentageoftheTotal
unitsproduced.
QUALITY=FullyProductiveTime
NetOperatingTime
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21. QUALITY=
Good Pieces/
Total Pieces
PERFORMANCE
=Actual Run
Rate/ Ideal Run
Rate
AVAILABILITY=
Operating time/
Planned
Production Time
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25. OEE= AVAILABILITY X PERFORMANCE X QUALITY
Availability = Operating Time / Planned Production
Time
Performance = (Total Pieces / Operating Time) / Ideal
Run Rate
Quality = Good Pieces / Total Pieces
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26. Thismethodusecomputersfor
accessinginputs,calculatingOEE
anditsanalysis.
E.g.:OEEIMPACT,VISUALOEE,
OEETOOLKIT,PROVIDEAMetc.
Spreadsheets
SystemSoftware
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27. oShift Length: 8 Hours
oTea Breaks: 10 Minutes x 2
oMeals Break: 1 Hour
oDowntime: 10% of shift
oIdle Runrate: 5 pieces/minute (Cycle
time=0.2min/pieces)
oTotal Pieces Produced: 1600
oRejected Pieces: 52
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28. OEE= Availability x Performance x Quality
Availability=OperatingTime/Planned
ProductionTime
PlannedProductionTime=PlantOperating
Time–PlannedShutdown
PlantOperatingTime=8hoursx60=480min.
PlannedShutdown=Teabreak+Lunch
Break=(10x2)+60=80minutes.
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29. PlannedProductionTime=480-80=400min.
OperatingTime=PlannedProductionTime-
DowntimeLoss=400-48=352minutes.
Availability=352/400=0.88
Performance=(TotalPieces/OperatingTime)/
IdleRunRate=(1600/352)/5=0.9091
Quality =GoodPieces/TotalPieces
=(1600-52)/1600=0.9675
OEE = 0.88 x 0.9091 x 0.9675 = 0.774
OVERALL EQUIPMENT EFFECTIVENESS= 77.4%
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30. OVERALL EQUIPMENT EFFECTIVENESS (EXCEL CALCULATOR)
Production Data
Shift Length 8Hours = 480Minutes
Short Breaks 2Breaks @ 10Minutes Each = 20Minutes Total
Meal Break 1Breaks @ 60Minutes Each = 60Minutes Total
Down Time 48Minutes
Ideal Run Rate 5PPM (Pieces Per Minute)
Total Pieces 1,600Pieces
Reject Pieces 52Pieces
Support Variable Calculation Result
Planned
Production Time Shift Length - Breaks 400Minutes
Operating Time Planned Production Time - Down Time 352Minutes
Good Pieces Total Pieces - Reject Pieces 1,548Pieces
OEE Factor Calculation OEE%
Availability Operating Time / Planned Production Time 88.00%
Performance (Total Pieces / Operation Time) / Ideal Run Rate90.91%
Quality Good Pieces / Total Pieces 96.75%
Overall OEE Availability x Performance x Quality 77.40%
OEE Factor
World
Class OEE
OEE%
Availability 90.00% 88.00%
Performance 95.00% 90.91%
Quality 99.90% 96.75%
Overall OEE 85.00%77.40% 28

31. World class OEE is a standard which is used to
compare the OEE of the firm.
OEE Factor WORLD CLASS
Availability 90%
Performance 95%
Quality 99%
OverallEquipment
Effectiveness
85%
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33. FULLY PRODUCTIVE
TIME
QUALITY
LOSS
PLANT OPERATINGTIME
PLANNED PRODUCTION TIME
PLANNED
SHUTDOWN
OPERATING TIME
DOWNTIME
LOSS
RUNNING TIME
STOP TIME
LOSS
NET OPERATING TIME
SPEED
LOSS
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34. UsabilitytakesintoaccountStopTime
Loss.
USABILITY = Running Time
Operating Time
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35. OEE
AvailabilityUsabilityPerformance Quality
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37. oShift Length: 8 Hours
oTea Breaks: 10 Minutes x 2
oMeals Break: 1 Hour
oWarm-up Time: 20 minutes
oEquipment Breakdown(Tool Failure): 28 min.
oIdle Runrate: 5 pieces/minute (Cycle
time=0.2min/pieces)
oTotal Pieces Produced: 1600
oRejected Pieces: 52
Downtime
Loss of 48
minutes (10%
of Shift)
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38. Availability = Operating Time/ Planned
Production Time
Planned Production Time = 400 minutes
Operating Time = Planned Production Time-
Breakdowns= 400-28 = 372 minutes.
Availability= 372/400 = 0.93
Usability = Running time / Operating Time
Running Time= Operating Time –Warm-up
Time = 372-20 = 352 minutes.
Usability= 352 / 372 = 0.9462
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39. Performance=(Total Pieces / Operating Time) /
Idle Run Rate = (1600 / 352) / 5 = 0.9091
Quality= Good Pieces / Total Pieces
= (1600-52) / 1600 = 0.9675
OEE = Availability x Usability x Performance x
Quality
OEE= 0.93 x 0.9462 x 0.9091 x 0.9675 = 0.774
Modified OVERALL EQUIPMENT
EFFECTIVENESS = 77.4%
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42. AnilS.Badiger,‘Aproposal:evaluationof
OEEandimpactofsixbiglosses’,Int.J.
ProcessManagementandBenchmarking,
Vol.2,No.3,2008,pp234-248.
RavikumarM.M.,‘ImprovingEquipment
Effectiveness’,Int.BusinessManagement,
Vol.3,No.2,2008,pp91-96.
www.bestmanagementarticles.com
www.maintenanceworld.com
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