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Performance

Evaluation &Incentive

Scheme for

Production

Supervisor

Bombay Rayon Fashions

Limited

07-Aug-13

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The Big Losses:

Breakdowns

Down Time Loss

Tooling Failures Unplanned Maintenance General Breakdowns Equipment Failure

Setup and

Adjustments

Setup/Changeover Material Shortages Operator Shortages Major Adjustments Warm-Up Time

Small Stops

Speed Loss

Obstructed Product Flow Component Jams Misfeeding Sensor Blocked Delivery Blocked Cleaning/Checking

Reduced Speed

Rough Running Under Nameplate Capacity Under Design Capacity Equipment Wear Operator Inefficiency

Startup Rejects

Quality Loss

Scrap Rework In-Process Damage Incorrect AssemblyProduction Rejects

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Benchmark Level:

OEE Factors Availability Performance Quality OEE

Benchmark Level 90 95 99 85

Example:

Availability (8

hours)

Performance (100

Pcs/hr)

Quality (Good Pieces/Total

Pieces)OEE

6 h 40 min 600 pieces 572 pieces

83.33 90 95.3371.49

Permutations & Combinations:

OEE Factors Availability Performance Quality OEE

1 85 90 99 75.735

2 80 90 99 71.28

3 85 85 98 70.805

4 90 80 97 69.84

5 88 78 96 65.8944

6 80 80 99 63.36

7 82 82 85 57.154

Incentive Scheme for Production Supervisor:

OEE Level Benefits

>75%

>70% - 75%65% - 70%