Total Productive Maintenance Overall Equipment Effectiveness
Total Productive Maintenance Overall Equipment Effectiveness
Total Productive Maintenance Overall Equipment Effectiveness
Target Audience :
Purpose of Module :
• Introduction
• Data Collection
• If you were told that your department was running flat out you might reasonably assume that the
equipment was running efficiently and effectively.
OEE =
AVAILABILITY
x PRODUCTIVITY
x QUALITY
OEE and the Six Big Losses
Equipment Six Big Losses
Planned Downtime
Total Available time
1 Breakdowns
Available time
2 Setup / adjustment
Available operating time
3 Idling / minor
stoppages
Actual operating
time 4 Speed
1 Breakdowns
Available time
2 Setup / adjustment
Available operating time
Planned v Unplanned Downtime
• Planned
– Excess capacity.
– Planned breaks.
– Planned Maintenance.
– Communications briefs / team meetings.
• Unplanned (Losses)
– Breakdowns.
– Set Ups and Adjustments.
– Late deliveries (material).
– Operator availability.
Note :
Planned time such as breaks, meetings and maintenance can be considered as losses (useful for
encouraging ideas on how to minimise their disruption) as long as a consistent approach is taken.
Productivity
“The difference between the potential output and actual output, when the equipment was
available”
• Productivity
– The Operating Speed Rate factored with interruptions to constant processing, i.e. idling and
minor stoppages.
Quality
“The total good parts produced expressed as a % of the total parts produced”
Actual operating
time 5 Defects in process
and rework
Effective
operating 6 Start up losses
time
Processed v Defect Quantity
• Parts Made
– The total quantity of parts produced in the available time.
• Defect Quantity
– The quantity of parts that did not meet the required standard (including rework) in the available
time.
OEE and the Six Big Losses
1 Breakdowns
Available time
2 Setup / adjustment
Available operating time
3 Idling / minor
stoppages
Actual operating
time 4 Speed
2 Setup / adjustment
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
Six Big Losses - What Are They ?
2 Setup / adjustment
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
Six Big Losses - What Are They ?
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
Six Big Losses - What Are They ?
2 Setup / adjustment
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
Six Big Losses - What Are They ?
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
Six Big Losses - What Are They ?
3 Idling / minor
stoppages
4 Speed
5 Defects in process
and rework
6 Start up losses
How to collect data for OEE
• Key Points
QUALITY
QUALITY
Defect
DefectQuantity
Quantity JJ
QUALITY
QUALITY KK==(G-J)/G
(G-J)/G
How to Eliminate Losses ?
How Do We Use OEE?
• OEE is only a measure, its benefits will be lost if the shortfalls it identifies are not acted upon.
• OEE is a total measure of performance but the data used to produce it must be used to prioritise
improvement tasks.
• The purpose of measurement is to identify losses, remove waste and drive improvement.
• OEE should be used to support the Total Productive Maintenance (TPM) approach and the tools it
supplies.
What are the benefits of OEE?
• FOCUS
– Highlight priorities for change.
• SIMPLICITY
– Even complex processes can be measured.
• FEEDBACK
– Before and after change.
• BENCHMARKING
– Objective comparisons.
• TARGET SETTING
– Setting achievable goals.
Solving Problems
Production
MRP
M/c # 1 Weekly
Daily Support NC OPS
OEE
OEE Log. Maint. Quality
X Hours
M/c # 2 OEE
OEE
LVER 2 24
Hours
Improve Performance
Improve Quality
Equip. uptime
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