What is OEE ?

OEE Definition

Making OEE part of Visual Management

OEE Overall Equipment Effectiveness

OEE Calculation

How can i influence the OEE ?

Why is a high OEE important for the department ?

KANZEN INSTITUTE ASIA PACIFIC

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 OEE is loss due to:
Depending on definition TPM knows 6-16 different losses

Planned Downtime Downtime Performance Losses Quality Losses

- breaks, planned maintenance, training

- breakdowns, repairs - changeover - adjustment - start up

- machine speed - short stoppages - lower yield

Productive time

Effective time

- scrap - reject - rework

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Calculation of LOSSES
Total time e.g. 480 min. (1 shift) Available time 420 min. Running time 340 min. Productive time 270 min. Effective time 250 min. Total losses = 170 min / shift
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Planned Downtime Downtime Performance Losses Quality Losses

- breaks, planned maintenance, training

- breakdowns, repairs - changeover - adjustment - start up - long cycle time - minor stoppages - reduced yield

- scrap - rework - rejects

Calculation of OEE
Running Efficiency = Available time - Downtime Availability 420 min - 80 min 420 min

OEE (in %) =
factor 81%

Productive Performance=

Running time - Performance loss Running time 340 min 70 min 340 min

X
factor 79.4%

Quality =

Productive time - Quality loss time Productive time 270 min - 20 min 270 min

X
factor 92.6%

Overall Equipment Effectiveness

KANZEN INSTITUTE ASIA PACIFIC

= 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 Data analysis and visible measure Analysis Make improvements visible and implement

Repairs Change over, Adjustm. Tool change

35 30 25 20 15 10 5

Autonomous Mainten. Preventive Maintenance Changeover reduction

Repair

Changeover Tool change

Scrap

Minor Stopp.

Minor stoppages Scrap, rework

33

26

16

Standardize tooling OEE Trend

Target 2003

Improved machine reliability Standardisation Kaizen

J F M A M J J A S O N D

KANZEN INSTITUTE ASIA PACIFIC

Making OEE visible

Machine Information
OEE trend machine 01
Target 2003
J F M A M J J A S O N D

Departement Information
OEE trend Machine 01
Target 2003

Company Information
Data
J FMAM J J ASOND

OEE Produktivity
J FMAM J J ASOND J FMAM J J ASOND J FMAM J J ASOND

J FMA M J J A SOND

OEE trend Machine 02

Target 2003

35 30 25 20 15 10 5

Analysis

J F M A M J J A S O N D

other OEE trend Machine 03

Target 2003
J FMAM J J ASOND Repairs Chgeover Tool chg. Scrap Min.Stop.

J FMAM J J ASOND

33

26

16

J F M A M J J A S O N D

shows the current situation of the machine or plant

shows the machine in the area

shows developement, trends and links beween targets and achievements

KANZEN INSTITUTE ASIA PACIFIC

Structured matrix sheet

company

Effects of OEE improvement activities

OEE in %

Date .

Department

target

effect of improvement project

2003

2004

Measures
introduction training
removal of defects elimination of defects standards / check lists improvement projects

KANZEN INSTITUTE ASIA PACIFIC

Fundamental concept of plant effectiveness

16 Kinds of loss

8 availability losses
Machine failure

5 productivity losses
Management losses
Motion Line organization Logistics Adjustments

3 production/ cost losses not part of OEE Loss of energy Die, Jig and tool losses Yield losses

Set up & adjustments

Tool changes Start-up losses Minor stoppages Speed Losses Defects and Rework Shutdown

KANZEN INSTITUTE ASIA PACIFIC