– OEE Materi Kuliah Sistem Perawatan | Blog Mas'ud Effendi
Overall Equipment Effectiveness
(OEE)
Sistem Perawatan
What is OEE ?
OEE
Definition
Making OEE
part of Visual
Management
How can i
influence
the OEE ?
OEE
Overall Equipment
Effectiveness
OEE
Calculation
Why is a high OEE
important for the
department ?
Overall Equipment Effectiveness
OEE is the way to measure how effectively machine / equipment hours are used
(Value Adding)
Total time
e.g. 480 min. (1 shift)
Available time
Running time
Productive time
Effective time
OEE is loss due to:
Depending on definition TPM® knows 6-16
different losses
Planned
Downtime
- breaks, planned
maintenance, training
Downtime
- breakdowns, repairs
- changeover
- adjustment
- start up
Performance
Losses
- machine speed
- short stoppages
- lower yield
Quality Losses
- scrap
- reject
- rework
Calculation of LOSSES
Total time
e.g. 480 min. (1 shift)
Planned
Downtime
- breaks, planned
maintenance, training
Running time
340 min.
Downtime
- breakdowns, repairs
- changeover
- adjustment
- start up
Productive time
270 min.
Performance
Losses
- long cycle time
- minor stoppages
- reduced yield
Quality Losses
- scrap
- rework
- rejects
Available time
420 min.
Effective time
250 min.
Total losses = 170 min / shift
Calculation of OEE
Availability
(Running Efficiency) =
=
Productive Performance=
=
Quality =
=
Available time - Downtime
Available time
420 min - 80 min
420 min
Running time - Performance loss
OEE (in %) =
factor 81%
X
Running time
340 min – 70 min
340 min
Productive time - Quality loss time
factor 79.4%
X
Productive time
270 min - 20 min
270 min
Overall Equipment Effectiveness
factor 92.6%
= 59.6%
How to increase OEE ?
Data collection is the very important basis to increase OEE
Collect data for all downtime
and losses on the machine
Repairs
Change over, Adjustm.
Tool change
Data analysis and
visible measure
Analysis
35
30
25
20
15
10
5
Autonomous Mainten.
Preventive Maintenance
Changeover reduction
Repair
Minor stoppages
Make improvements
visible and implement
33
Changeover Tool change
26
16
Scrap
Minor Stopp.
7
3
Standardize tooling
Scrap, rework
OEE Trend
Target 2003
Improved machine
reliability
Standardisation
Kaizen
J F M A M J J A S O N D
Making OEE visible
Machine Information
OEE trend machine 01
Target 2003
Departement Information
Company Information
OEE trend Machine 01
Target 2003
Data
J FMAM J J ASOND
J F M A M J J A S O N D
J FMA M J J A SOND
OEE trend Machine 02
OEE
Produktivity
Target 2003
J FMAM J J ASOND
J FMAM J J ASOND
J FMAM J J ASOND
Analysis
35
30
25
20
15
10
5
J F M A M J J A S O N D
other
J FMAM J J ASOND
OEE trend Machine 03
Target 2003
J FMAM J J ASOND
Repairs Chgeover Tool chg. Scrap Min.Stop.
33
26
16
7
3
shows the current situation
of the machine or plant
J F M A M J J A S O N D
shows the machine
in the area
shows developement, trends
and links beween targets and
achievements
Structured matrix sheet
Effects of OEE improvement activities
company
Date
.
Department
OEE
in %
target
effect of improvement project
2003
2004
Measures
introduction training
removal of defects
elimination of defects
standards / check lists
improvement projects
t
Fundamental concept of plant effectiveness
16 Kinds of loss
8 availability losses
5 productivity losses
3 production/ cost losses
– not part of OEE -
Machine failure
Management losses
Set up & adjustments
Motion
Loss of energy
Tool changes
Line organization
Die, Jig and tool losses
Start-up losses
Logistics
Minor stoppages
Adjustments
Speed Losses
Defects and Rework
Shutdown
Yield losses
(OEE)
Sistem Perawatan
What is OEE ?
OEE
Definition
Making OEE
part of Visual
Management
How can i
influence
the OEE ?
OEE
Overall Equipment
Effectiveness
OEE
Calculation
Why is a high OEE
important for the
department ?
Overall Equipment Effectiveness
OEE is the way to measure how effectively machine / equipment hours are used
(Value Adding)
Total time
e.g. 480 min. (1 shift)
Available time
Running time
Productive time
Effective time
OEE is loss due to:
Depending on definition TPM® knows 6-16
different losses
Planned
Downtime
- breaks, planned
maintenance, training
Downtime
- breakdowns, repairs
- changeover
- adjustment
- start up
Performance
Losses
- machine speed
- short stoppages
- lower yield
Quality Losses
- scrap
- reject
- rework
Calculation of LOSSES
Total time
e.g. 480 min. (1 shift)
Planned
Downtime
- breaks, planned
maintenance, training
Running time
340 min.
Downtime
- breakdowns, repairs
- changeover
- adjustment
- start up
Productive time
270 min.
Performance
Losses
- long cycle time
- minor stoppages
- reduced yield
Quality Losses
- scrap
- rework
- rejects
Available time
420 min.
Effective time
250 min.
Total losses = 170 min / shift
Calculation of OEE
Availability
(Running Efficiency) =
=
Productive Performance=
=
Quality =
=
Available time - Downtime
Available time
420 min - 80 min
420 min
Running time - Performance loss
OEE (in %) =
factor 81%
X
Running time
340 min – 70 min
340 min
Productive time - Quality loss time
factor 79.4%
X
Productive time
270 min - 20 min
270 min
Overall Equipment Effectiveness
factor 92.6%
= 59.6%
How to increase OEE ?
Data collection is the very important basis to increase OEE
Collect data for all downtime
and losses on the machine
Repairs
Change over, Adjustm.
Tool change
Data analysis and
visible measure
Analysis
35
30
25
20
15
10
5
Autonomous Mainten.
Preventive Maintenance
Changeover reduction
Repair
Minor stoppages
Make improvements
visible and implement
33
Changeover Tool change
26
16
Scrap
Minor Stopp.
7
3
Standardize tooling
Scrap, rework
OEE Trend
Target 2003
Improved machine
reliability
Standardisation
Kaizen
J F M A M J J A S O N D
Making OEE visible
Machine Information
OEE trend machine 01
Target 2003
Departement Information
Company Information
OEE trend Machine 01
Target 2003
Data
J FMAM J J ASOND
J F M A M J J A S O N D
J FMA M J J A SOND
OEE trend Machine 02
OEE
Produktivity
Target 2003
J FMAM J J ASOND
J FMAM J J ASOND
J FMAM J J ASOND
Analysis
35
30
25
20
15
10
5
J F M A M J J A S O N D
other
J FMAM J J ASOND
OEE trend Machine 03
Target 2003
J FMAM J J ASOND
Repairs Chgeover Tool chg. Scrap Min.Stop.
33
26
16
7
3
shows the current situation
of the machine or plant
J F M A M J J A S O N D
shows the machine
in the area
shows developement, trends
and links beween targets and
achievements
Structured matrix sheet
Effects of OEE improvement activities
company
Date
.
Department
OEE
in %
target
effect of improvement project
2003
2004
Measures
introduction training
removal of defects
elimination of defects
standards / check lists
improvement projects
t
Fundamental concept of plant effectiveness
16 Kinds of loss
8 availability losses
5 productivity losses
3 production/ cost losses
– not part of OEE -
Machine failure
Management losses
Set up & adjustments
Motion
Loss of energy
Tool changes
Line organization
Die, Jig and tool losses
Start-up losses
Logistics
Minor stoppages
Adjustments
Speed Losses
Defects and Rework
Shutdown
Yield losses