5 OEE Loss Tree

7/17/2019 5 OEE Loss Tree

http://slidepdf.com/reader/full/5-oee-loss-tree 1/30

Basics of OEE Loss Tree



Why Effective Maintenance?

Equipment Breakdown80%

90%Do you think this

5.57%

60%

70%

40%

50% AAMET Loss Structure

5.21%

20%

30%

Changeovers

2.02%

0%

10%

Equipment Breakdown 5.57

Minor Stoppages 5.21Changeovers 2.02

s a o a



16 Big LossesLost Tree

120%

41%

62%

40%

60%

80%

20% 21%38%

2% 4% 9%

14%22%

0%

20%

S T A R

T U P

N T &

A D J

S E R V

I C E

G E O V E

R

E W O R

K S

O G I S

T I C S

T O P P

A G E

A K D O

W N

M E A S

U R E

R E L I G

I O U

C H A

D E F E

C T &

M I N O

R

E Q . B R

Minor Stoppages 100%

60%

80%

100%

120%

Breakdown100%

80%

100%

120%

34% 44%7%

14%22%

0%

20%

40%

h e r s

c t i o n n t

r o l

s t e m t u

r e

19%

52%

3% 6% 10%16%

22%29%

48%

0%

20%

40%

m m r s i l l o l o n r e m

A C M A

S

P a p e

r C

W r a p

p i n g S

D i e s T e

m p e

C o n t

r o l S

y s t

A C M A

H e a t i n g S

y s t

O t h

P a p

e r C o n

A C M

A S u c

t

D i e s T e

m p e

r a t

W r a p p i n

g S y s

t

Dies Temperature Wrapping

Priori ty to be solved



16 Big Losses in Manufacturing

e

Awaiting

Instruction

7 Major Losses which obstruct Overall Equipment Efficiency (OEE)5 Major Manpower Losses

(accompany the 7 major losses in equipment)

Working hour

Loading Time

u own os ses

(1) Equipment Failure

Loss

S c h e d u l e d d o w n t i

Operating man hour

Loading man hour(9) Management

Awaiting

materials

loss

Operating Time

Net

Operating TimeValued

Cleaning

checking

et-up an

Adjustment Loss

(3) Cutting blade and

jig change Loss

Downtime Loss

Performance Loss

Net Operating

man hour

Effective

man hourValued

oss

(10) Operating Motion

Loss

Equipment Downtime loss

Operating TimeAwaiting

Instruction

Awaiting

materials

Awaiting

(4) Start-up Loss

Other downtime Loss

Defects

Quality

Loss

man hourEquipment Performance loss

Method/Procedures loss

Skill & moral loss

3 Major Losses which obstruct Efficiency of

material,die,jig,tool and energy

personne

distribution

Quality

confirmation

(adjustment of

measurement)

(5) Minor Stoppages

& idling Loss

(6) Speed Loss

(11) Line OrganisationLoss

Line Organisation loss

Automatization failure loss

(15) Energy Loss

Start-up loss

Overload loss

(14) Yield Loss

Defects quality loss

Start-up loss

Cutting loss

(7) Defects

& Rework Loss

(12) Logistics

(13) Measurement &Adjustment loss

Temperatureosses n we

Losses in overages

(16) Die, tool & jig Loss



Semua Losses - > Biaya

1 Equipment Breakdown

2 Set U / Chan e Over

T

3 Aktivitas Rutin

4 Start Up / Ramp Down

5 Minor Stoppage

7 Major Equipment Losses ta

l6 Speed

7 Defects and Rework

8 ShutdownShutdown Loss

i

m

o

s

L

oanagemen

10 Operational Motion

11 Line Organisation5 Major Manpower Losses

e s

s

e

og s cs13 Measurement & Adjustment

14 Energy3 Ma or Material & Ener

C C

o15 Maintenance Spare Parts

16 YieldLosses

s

t

s

t



7 losses Penghambat OEE

100% Aktivitas Rutin Aktivitas Rutin

i t y

C a p a b i l

Time

Start-Up Minor Stoppages Defects Failures/

Breakdown

Setup &

Adjustment

(C/O)

Ramp-Down



1. Failure Loss (Breakdown)

Ini adalah loss karena mesin berhenti (tidak diharapkan) yangsama atau lebih dari 10 menit, dan terjadi secara sporadik

.

Contohnya :. o or er a ar

2. Shaft patah

3. Bearing Macet

Note : Jika kerusakan berlangsung ke shift berikutnya (misalnya karena

tidak ada spare part, maka shift berikutnya akan dihitung sebagai PM)



Failure Loss (Breakdown)

100% Capabil ity

Failures

Time



2. Set-up / Change Over Loss

dari produk 1 ( pada speed dan kualitas normal ) ke produklainnya ( pada kecepatan dan kualitas normal ).

Loss ini termasuk Change Over Packaging,Size, & Variant.

Elemen yang paling lama ketika melakukan Change Over

adalah test-running dan adjusment ( penyetelan ).



Set-up / Change Over Loss

100% Capabil ity

Failures Setup / Change

Over

Time



3. Routine Activity (Aktivitas Rutin) Loss

Loss yang terjadi akibat pemberhentian mesin rutin untuk

mengganti mata gerinda, mata gergaji, cutter ketika sudah

tum ul atau rusak chan e blade .

Loss ini juga termasuk penggantian wrapper, cleaning rutin di

pertengahan minggu (misalnya tiap shift), dll.



Routine Activity Loss

100% Capabil ity

Aktivitas Rutin Aktivitas Rutin

Failures Setup & C/O

Time



4. Start Up/Ramp Down Loss

.

mulai dari mesin dijalankan sampai mencapai kondisi stabilpada kecepatan normal dan kualitas produk yang bagus.

Start Up Losses dapat terjadi setelah :

- Perbaikan rutin (PM)

- Mesin berhenti dalam waktu an lama

- Liburan- Istirahat makan



Start Up/Ramp Down Loss

100% Capabil ity


Start-Up

LossFailures Setup & C/O

TimeRamp-down

Loss



5. Minor Stoppages & Idling Loss

,

mengakibatkan mesin berhenti sesaat dan jalan lagi dalamwaktu yang relatif singkat ( kurang dari 10 menit ).

Hal ini biasanya terjadi karena produk tersangkut pada suatu

bagian mesin atau ketika produk defect mengaktifkan sensor

an men hentikan mesin.Pada kasus-kasus ini, produk hanya perlu dipindahkan dan

mesin di-reset untuk dijalankan kembali.



Minor Stoppages & Idling Loss

100% Capabil ity


Start-Up

LossMinor Stoppages

and IdlingFailures Setup & C/O

TimeRamp-down

Loss



6. Speed Loss

Loss ini ter adi karena erbedaan s eed antara desi n s eed

mesin terhadap speed aktual mesin ketika jalan.Ketika mesin dijalankan pada design speed, kadang-kadang

,

operator menurunkan speed mesin.

Ada 2 tipe Speed Loss :

- Loss karena perbedaan antara actual speed dengan standard speed.- Loss yang diakibatkan karena design speed lebih rendah dari teknologi

saat ini ataupun kondisi yang diinginkan.



Speed Loss

100% Capabil ity

pee oss Aktivitas Rutin Aktivitas Rutin

Start-Up

LossMinor Stoppages

and IdlingFailures Setup & C/O

TimeRamp-down

Loss



7. Defect and Rework Loss

Waktu yang digunakan untuk menghasilkan produk yang reject

dan juga waktu yang digunakan untuk menghasilkan

waste/rework.

Material/energi yang berkaitan dengan rework ini akan dihitung

pada Energy & Yield Loss.



Defect and Rework Loss

100% Capabil ity

pee oss Aktivitas Rutin Aktivitas Rutin

Start-Up

LossMinor Stoppages

and IdlingDefects Failures Setup &C/O

TimeRamp-down

Loss



Loss mempengaruhi Utilisasi

8. SHUTDOWN LOSS adalah loss akibat scheduled downtime

(planned stoppages). Ini adalah waktu yang yang dijatah tidak

.

tanggung jawab management atau engineering, bukandepartemen produksi.

Loss ini termasuk :

- Holidays (hari libur)- o ro uct on r ers t a a a rencana pro u s m sa nya arena :

planner tidak membuat planning, training, teambuilding, dan 3 masalah yang

diketahui 1 shift sebelumnya yaitu tidak ada operator, tidak ada utility, & tidak ada

material.

- Planned Modifikasi- Planned Maintenance ( PM), termasuk kerusakan mesin/perbaikan (yang

diketahui 1 shift sebelumnya), tidak ada spare part (yang diketahui 1 shift

se e umnya .

- Planned Trial (trial dev (produk, packaging), trial engineering)

- Sholat Jumat



5 Loss impeding Labor Effectiveness

9. MANAGEMENT LOSS

problems, such as failure to provide materials, spare parts,utilities, waiting instructions, etc

10. OPERATIONAL MOTION LOSS

This include losses created as a result of difference in skilllevels and losses attributable to inefficient layout, e.g.

walking loss

.Loss resulting from the shortage of Operators on the line,

-. .

than was originally planned while he don’t have necessary

skills to operate multi lines



5 Loss impeding Labor Effectiveness

12. LOGISTIC LOSS

Time wasted in inefficient delivery of raw, packing,products, etc to the line and removal of finished products

from the line.

13. MEASUREMENT & ADJUSTMENT LOSS

These are worker-hour losses that result from frequent

implementation of measuring and adjustment to prevent

occurrence o qua y e ec s an ow ou .



3 Loss impeding Resource Cons.

14. ENERGY LOSS

processing, e.g. start up loss, idling loss.15. DIE, JIG AND TOOL LOSS

These are monetary losses resulting from the

manufacturing and repair of dies, jigs and tools necessary

,

supplementary supplies such as cutting & grinding fluid

16. YIELD LOSSIs the difference between the weight of material fed into

.

material losses in the form of defective product, give away,

over pack, leaks, spills, evaporation, etc



OEE Concept

Mengukur performa lines berdasar tiga

kategori dan 16 loss yang didefinisikan olehTPM

OEE = Availability x Performance x Quality



OEE Concept ( cont’d )

Secara sederhana

OEE = Actual output/ Standard Output

Machine dengan sign off speed 100 ppm

berproduksi 1 shi t ( 8 jam ), machine lancar

dengan out put 25000 product.

Perhitungan :

EE = 25000/(100*480)x100 = 52



OEE & CU

=CU

Total Time

OEE

Notes:

• Standard Cycle Time is based on Line Design speed

• Defects include waste and reworked units



Link between Losses & Reasons

4Holidays / Weekends / Factory Shutdown4No production orders

4Planned Maintenance4Planned Modification

48- Shutdown

4Losses Level 4Reasons Level (Some Examples)

4Loading Time u t d o w n

s e s 41- Equipment Breakdown

42- Chan eover

4Breakdown (>10´)

4Changeover - format4Changeover - product

4Shutdown of the Packing Line

4Operating Time 4 D

o w n t i m e

4

L o s s e s

S h

L o

43- Cutting Blade Change

44- Start-up / Ramp down

49- Management

410- Operational Motion

app ca e4Start up of the Packing Line4Failure to provide material4Utilities Stops due the sites reasons4

Power Cuts from Government4

4Net

4Operating

4Time 4

P e r f o r m a n c e

4

L o s s e s

45- Minor Stoppages

46- Speed

411- Line Organisation

4Minor Stoppages (<10´)

4Should be calculated automatically

4Meals break & Prayer Breaks4Unexpected lack of operators

4

Lack of product from the process area4

Value4Operating

4Time 4

D e f e

c t s

4

L o s s e s -

47- Defects and rework 413 – Measurement &Ad ustment

4Quality problem with product4Quality problem with Packaging

4Cleaning routine4 4 -

415 - Maintenance spare parts

416 - Yield

4Machine Adjustment



Contoh 2

Packaging Machine standard speed 100 ppm

berproduksi selama 1 shift atau 8 hr

selama 1 jam

Terjadi beberapa minor stop

.

Hitunglah OEE-nya



Jawaban contoh 2

Availability = ( 8-1)/8*100%=87,5%

Performance = 36000/(100*60*7)=85,7%

OEE = 74,98%

Documents

5 OEE Loss Tree