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OEE Definitions
Thinking win, Win, WIN
The Mystery of OEEDefinitions
Marek Piatkowski – April 2016
Thinking win, Win, WIN
OEE Definitions
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
OEE Definitions
Thinking win, Win, WIN
TPM Implementation should be driven by the following phrase.
“THIS IS THE WORST CONDITIONTHIS EQUIPMENT HAS EVER BEEN IN”
OEE Definitions
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Operational Availability The time that a machine operates maintenance free as a
percentage of the time during it is switched on. This is equivalent to the reliability of equipment and its
maintenance The ideal condition is to have 100% operational availability during
the time the machine is switched on to fill production orders.Rate of Operation The rate of operation states the actual production levels being
achieved by equipment This is the percentage of total production capacity actually
produced during regular work hours as determined by demand. This rate of operation itself changes depending upon sales.
OEE Definitions
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OEE - Improvement Measurements OEE - Overall equipment effectiveness measures how the plant is
performing relative to reducing the equipment losses and conditions which prevent customer satisfaction
The OEE improvement measurement is the product of three different measurements:
EA - Equipment AvailabilityEEP - Equipment Efficiency
PerformanceEQP - Equipment Quality
Performance
OEE Definitions
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EA – Equipment Availability EA - is a basic TPM performance measurement. EA measures how often equipment is not producing units
(unplanned downtime) due to breakdown or adjustment losses. It compares the actual time the equipment was producing units (uptime) to the time it was scheduled to produce units (scheduled production time).
A breakdown is defined as a condition which requires assistance of a specially trained maintenance technician or an engineer
Equipment adjustments are should be normally performed by operators
Unplanned downtime does not include breaks, lunches, personal relief, team meetings or scheduled maintenance.
EA
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EA – Equipment Availability
Uptime
EAUptime = Scheduled Production Time - Unplanned Downtime
X 100 %EA =Scheduled Production Time
EA percentage (%) gives the actual time the machine is running versus what it should be running
OEE Definitions
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What is a Down Time Clock?
Down Time Clock is a simple method to measure (EA), total duration of machine stops – regardless of the reasons or causes
In it’s simplest form it is an analog clock connected to the “logic” of a machine or an automated process
At the start of the shift the clock is reset to 12:00 When machine is operating – the clock is not running. When the
machine stops – the clock starts to run. This way at the end of a work period (for example a shift) you can
have an accurate read-out how many minutes the machine was not running.
In the example on the next slide the machine was not running for almost 2 hours and 50 minutes – 170 minutes down time per shift
How accurate is your down time? You might surprise yourself
OEE Definitions
Thinking win, Win, WIN
EEP – Equipment Efficiency Performancee
EEP - measures the actual machine cycle time versus the theoretical or “standard” cycle time.
It compares the actual number of units produced versus the “standard” number of units the machine should have produced in a given length of time (uptime)
Uptime is the same number that was previously defined in the EA calculation.
The standard cycle time assumes there are no minor stoppage losses or reduced speed losses.
Minor stoppages are defined as stoppages which can be corrected by the operator
EEP
OEE Definitions
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EEP – Equipment Efficiency Performance
EEPX 100 %EEP =
Actual Run TimeStandard Cycle Time x # of Units Produced
EEP percentage shows the percent of units produced versus the“standard” quantity that should have been produced.
The number of Units Produced also includes any defective units that were produced during that period of time.
OEE Definitions
Thinking win, Win, WIN
EQP – Equipment Quality Performance
EQP - measures the performance of the machine from a quality standpoint.
It compares the number of good units to the total number of units produced for a given period of time.
Defective units can be produced when equipment does not perform properly or during machine start-up, before the process has stabilized.
Parts which can be reworked are counted as defective.
EQP
OEE Definitions
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EQP – Equipment Quality Performance
EQP # of Good UnitsX 100 %EQP =
Total # of Units Produced
# of Good units = Total # of Units Produced - Total # of Units Defective
EQP percentage shows the quality performance of equipment
OEE Definitions
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OEE – Overall Equipment Efficiency
OEE = EA x EEP x EQP
Benchmarks for these measurements are:
EA = 90% EEP = 95% EQP = 99% OEE = 85%
OEE
OEE Definitions
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Availability
Greater than 90%
Running TimeNet Operating Time
BA =
Overall Equipment Effectiveness =Availability x Performance rate x Quality rate 85%+
Idling and minor stoppages permachine (under 10 minutes)...less than 3 times/month
Idling &minorstoppages3
Operation speed increased...increase 15% or moreSpeed4
Quality defects in process(including products to bereworked)...less than 0.1%
Quality defectsin process &rework
5
Raw material yield...greater than 99%Startup6
Setup & adjustment time...less than 10 minutes
Setup/adjustment2
1 BreakdownsMachine down no longer than10 minutes...less than once a month
Average total operating loss30 - 50%
Performance rate
Greater than 95%
Actual OutputTarget Output
DC =
Total yield
Throughout process > 99%
Good OutputActual Output
FE =
Equipment
Dow
ntim
elo
sses
Spee
dlo
sses
Qua
lity
loss
es
Total operating time
Running time
GoodOutput
Optimal conditions in "man-machine" system
Increase continuous unmanned operation time
Equipment operation and the six big losses Improvement Targets
Not
Sche
dule
d
Net operating time
Target Output
Actual Output
Actual Output
A
B
C
D
E
F
OEE
OEE Definitions
Thinking win, Win, WIN
Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Thinking win, Win, WIN
OEE Definitions
Thinking win, Win, WIN
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