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1、 Introduction OEE Definition OEE measurement OEE case study OEE analysis and improvement New investment requestsContents OEE measurement and improvement must be implemented: For heavy and expensive means that are a bottleneck comparing to the customer demand in order to deliver, then, in order to pr
2、ovide datas to request a new investment Introduction OEE Definition OEE measurement OEE case study OEE analysis and improvement New investment requestsContents OEE rate Calculation (%) Added value Operating time = Nb of good parts produced x Standard Cycle Time Nominal opening time = Days of the wee
3、k when the factory is open on a regular basis (ie including management, support functions,.)OEE =Added value Operating timeNominal opening timeStandard Cycle Time = The best ever observed respecting quality criteria Introduction OEE Definition OEE Measurement OEE case study OEE analysis and improvem
4、ent New investment requestsContentsOEE : Category of losses1 Planned stops (meals, breaks, training, meeting, planned maintenance, tests)2 Machine breakdowns and no planned maintenance6 Micro-stoppage and Slow down (what is left over after deducting the 6 other causes of losses) 5 No Quality (Parts
5、manufactured but not good and rework)No OEE losses4 Organizational stops (Lack of tool, material, worker, punctual lack of load) 3 Change over timeTotal Available Time365 days x 24 hoursValue added operating time *Factory not opened on a regular basisOEE (%)100 (%)Nominal opening time7 Equipment not
6、 open but factory open* Nb of good parts produced x Standard cycle time)What are Cycle time and Change over time?PRODUCT A1st PRODUCT BQuality not yet OKPRODUCT BQuality OK4Cycle Time (CT) = Time spent between I load part A until I load next part A CTCT4Change Over time (C/O) = time between last goo
7、d part “A” and first good part “B”C/O timeUnloadingLoadingPRODUCT ATransformationCTUnloadingLoadingTransformationHow to track losses? “Production tracking form”4Standard form to be used: ATDPRO_APS_production tracking form_FC_*.xls Introduction OEE Definition Measurement OEE case study OEE analysis
8、and improvement New investment requestsContentsOEE case study4Thursday AM:Machine data recorded during one week:Part TypeABCGood parts753Rejects110Cycle Time5h2h1hNo OEE ReasonsNo instruction to work :8 hChange over1 h per C/O, 5 C/O per weekMaintenance for breakdown 3 hLack of worker1 worker during
9、 one shiftMachine breakdowns2 hMissing parts 1 hBreak30 min per shiftOEEAvailable Time : OEE calculation for one week :7 75 53 35 h5 h2 h2 h1 h1 h35 h35 h10 h10 h3 h3 h48 h48 h120 h120 h= 5 x = 5 x 24 h24 h 40 40Openning Time? OEE analysis :1 Planned stops (meals, breaks, training, meeting, planned
10、maintenance, tests)2 Machine breakdowns and non planned maintenance6 Micro-stoppage and Slow down (what is left over after deducting the 5 other causes of losses) 5 No Quality (Parts manufactured but not good and rework)4 Organizational stops (Lack of material, tool, operator, punctual lack of load)
11、 3 Change over time 7 Time during which the equipment isnt open and thus not supposed to work/Recorded by using: “Production tracking” formCalculated/小的停机小的停机或速度减缓或速度减缓Recorded at mana-gement level1,5 h / day x 5 days计划停机时间1 h breakdown + 3h repair 非计划停机时间5 x 1h产品转换时间4 h + 1h管理缺失停机时间 1 A , 1 B and 0
12、 C 1 x 5 + 1 x 2 + 0 x 1质量不合格时间No work on third shift = 5 x 8h计划停产时间 No-OEE analysis :6 Micro-stoppage and Slow down (what is left over after deducting the 6 other causes of losses) =40 h=7,5 h=4 h=5 h=5 h=7 h68,5 h120 h 48 h 68,5 h3,5 h1 Planned stops (meals, breaks, training, meeting, planned main
13、tenance, tests)2 Machine breakdowns and non planned maintenance5 No Quality (Parts manufactured but not good and rework)4 Organizational stops (Lack of material, tool, operator, punctual lack of load) 3 Change over time 7 Time during which the equipment isnt open and thus not supposed to work1,5 h /
14、 day x 5 days1 h breakdown + 3h repair 5 x 1h4 h + 1h 1 A , 1 B and 0 C 1 x 5 + 1 x 2 + 0 x 1No work on third shift = 5 x 8h=4No-OEE Pareto34%6%6%4%4%3%3%Open time not usedNo-OEE = 60%Planned stopsNo qualityChange overOrganiza-tionnal stopsBreak downMicroStoppage Introduction OEE Definition OEE meas
15、urement OEE case study OEE analysis and improvement New investment requestsContents How to improve OEE ?Decrease no quality?Decrease break down?Decrease organisational stops?Decrease change over time?/ How to improve OEE ?No way ! It is by increasing customer demand So : increase equipment available
16、 time Step 1 : Decrease CT, by decreasing loading and unloadingTransformationCTUnloadingLoadingTransformationCTUnloadingLoading Step 2 : OEE compared to potential100 %(basis = Factory nominal opening time) OEE (%)Losses Step 3 : No-OEE = Pareto 1%Total = No-OEE (%) Step 4 : Select the main causes an
17、d make a new Pareto if it is worth% Step 5 : Decrease No-OEE2 types :Changer OverOthers no-OEE Step 5 : Decrease No-OEE Change OverX %Change over timeProduction time / dayAvailable time to Change Over is a DECISIONSMED action is needed to reach the time decidedNothing needed to do4Step 5 : Decrease
18、No-OEE Change OverIf daily C/O time DecisionOrganizationThey are unacceptable4Step 5 : Decrease No-OEE Others no-OEESet up simple actions considering analysis and follow results by monitoringwWhen main loss cause is Organizational Stops Step 5 : Decrease No-OEE Others no-OEESet up simple actions con
19、sidering analysis and follow results by monitoring When main loss cause is No QualityNo QualityMRPG action is neededBreakdownTPM action is needed4Step 5 : Decrease No-OEE Others no-OEESet up simple actions considering analysis and follow results by monitoringwWhen main loss cause is Break Down Introduction OEE Definition Measurement OEE case study OEE analysis and improvement New investment requestsContentsMinimum requirements for a new investment OEE compared to potential Pareto 1 & 2, analysis and improvements Example of tracking form