SIX SIGMA IMPROVES OEE performance from 20% to 39.1%

Six Sigma improves OEE

1. Six Sigma improvesOEE
December172021
Prepared by Julian Kalac, P.Eng
Lean Six Sigma Master Black Belt

2. PROBLEM 2021 OEEbelow 20%
0%
10%
20%
30%
40%
50%
60%
70%
Jan Feb Mar April May June July Aug Sept Oct Nov Dec
2021 OEE
Industry standard=85%

3. WHAT DO YOU WHEN YOU DON’T KNOW WHAT TO DO?
1-Go back to the formula
verify the formula is
correct
2-Analyze the data, what
does the data say?
3-Test, and Verify the Data

4. OEE=
Availability
Run \Time
Total time
Production Qty /
QPRx Run time
Performance
Quality
Good Qty
Total Qty
STEP 1 VERIFY THE FORMULA

5. Input
Output
OUTPUT
CAM PACKAGING MACHINE INPUT OUTPUTWHERE IS
THE BOTTLENECK?

6. The CAM packaging line
●Based on current bottleneck (case packer cycle time of 3.33 min
/case the QPR= 72 cartons /min ,or QPR= 4320/hr)
Cartoner
120/min
72 cartons/min
Process Flow
Case
Packer
72 cartons/min = Target Throughput

7. STEP 2--ANALYZE THE DATA

8. ANOVA statistical comparison between shifts
P=0.00
means shift 3 is significantly
different from other shifts
P=0.00
significant

9. Shift 3 Max = 75
cartons/min
SHIFT 3 Avg= 75
Cartons/min
Shift3>Target (72)

10. Shift 2 Max = 62
cartons/min
SHIFT 2 Avg= 62
Cartons/min
Shift 2 <Target (72)

11. Shift 1 Max = 52
cartons/min
SHIFT 1 Avg= 52
Cartons/min
Shift 1 <<Target (72)

13. Step 3—Verify Data

14. 2021 OEECAM line @ 71 cartons /min
Avg= 25.2%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
Jan Feb Mar April May June July Aug Sept Oct Nov Dec
39.0%
24.1%
31.1%
21.2%
22.3%
24.1%
39.3%
21.2%
24.7%
31.6%
38.0%
39.1%
CAM OEE 2021 at 71 cartons /min
OEE
New OEE = 39.1%

15. World Class OEE –85% OEE