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Manufacturing Losses
Industry has traditionally used Labour Efficiency to set targets for Numbers produced per day and measure performance.
Target =
Efficiency =
This is appropriate for manual processes. Except that it induces all kinds of bad behaviours.
SSG06101ENUK Delegate Slides/Issue 1.1/ April 2008
Manufacturing Losses
For machine based processes this efficiency measure is inappropriate:
Emphasis is focused on Labour The target becomes a quota; either easy, too hard or occasionally just right Machines breakdown or run at a particular speed regardless of how many people are in attendance or how hard they work Machine downtime is lost once labour is redeployed
Companies working out their OEEs for the first time are taken aback by 20-30% performance
Production Engineering often own the plant. Whats the bottle neck process? Can it be speeded up? Why does the plant produce defects? Why do minor stoppages occur? Often a big contributor - count them
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But
Dont forget schedule attainment high OEE making something a customer doesnt want is waste OEE plant wide is an average nonsense. Target critical machines Bottle necks then Pareto Dont make OEE an end in itself, be sensible with cost of improvements ie large cost vs small gain would be counterproductive waste
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0.95
0.92
0.99
0.87
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An example
OEE at .
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Availability
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We know that team meetings, walking to breaks, washing, etc will eat into OEE. Remember that 85% is a world class auto factory where lockers, canteen ,etc are lineside.
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Down Time
The plant suffered: 3 minor breakdowns less than 10 minutes these are neglected ~(counted as performance) A major breakdown of 1 hour
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Availability
Running Time DownTime 100% RunningTim e 435 60 Availability = 100 = 86.3% 435 Availability =
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Performance
Suppose in the day we produced 1200 items % Performance = Machine Run rate x Processed Amount x 100 Operating Time
ie
% Performance = 56.25%
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Suppose 40 items (of the 800) failed inspection and were scrapped:
% of Right First Time Products = 800 - 40 x 100 = 95% 800
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Overall OEE
OEE = Availability Performance Quality 100% OEE = .863 .5625 .95 = 46.12%
Why did the breakdown occur? Why did it take an hour to fix?
Did the fitter turn up quickly? Did he have the part needed for repair to hand?
Did the crew take a break when the machine was down (rather than at the appointed time when it was back up again)? What can be done to reduce a 5% scrap rate?
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Golden Rules
OEE is about Machines NOT people OEE cannot exceed 100% 85% is World Class - Car Factory USE OEE to identify & correct Manufacturing Weaknesses Ask What if
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Operation:
D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
Event No.
Duration
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
H: Rounds Scrapped
J: Operating Time:
Availability : OEE :
Performance:
E. 'Machine Losses
Breakdow n losses Idling & Minor Stoppages E11 Sudden mechanical failure * E41 Breakdow n of previous machine E12 Sudden electrical f ailure * E42 Breakdow n of subsequent machine E13 PLC or softw are system failure * E43 Component jamming / remove & reset E14 Misc (please specify) Start up Losses E61 Machine not stable on start-up Set-up adjustment losses E21 Setting / Adjustments
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C44 Change process lubricant D. ' Method Losses Planned Maintenance Activities C21 Scheduled PPM activities Duplication D11 Operation repeated Development C51 Training
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Date / Shift
19/10/2004
Store/Product
Rarden case
Operation:
closing D=B-A-C
Cell:
Main manf plant area 5 Minutes/Piece
E:Machine Rate:
0.1 minute/item
Event No.
1 2
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed cap feeder jammed cap feeder spare fetched from Fitter's store
H: Rounds Scrapped
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J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C44 Change process lubricant D. ' Method Losses Planned Maintenance Activities Duplication C21 Scheduled PPM activities D11 Operation repeated Developm ent C51 Training
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Grp 4
Date / Shift
19/10/2004
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed feeder jammed feeder spare fetched from Fitter's store
435 - 75 = 360mins
H: Rounds Scrapped
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J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C44 Change process lubricant D. ' Method Losses Planned Maintenance Activities Duplication C21 Scheduled PPM activities D11 Operation repeated Developm ent C51 Training
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Grp 4
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
End Time
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed cap feeder jammed cap feeder spare fetched from Fitter's store
360/435x100 = 82.7%
F: Total Duration of Lost Time (mins)
D- F 75 mins J divided by D x100
H: Rounds Scrapped
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J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planned Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities D11 Operation repeated Development C51 Training
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Grp 4
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed cap feeder jammed cap feeder spare fetched from Fitter's store
H: Rounds Scrapped
10
J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical f ailure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planned Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities D11 Operation repeated Development C51 Training
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Grp 4
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed cap feeder jammed cap feeder spare fetched from Fitter's store
2000/(2000+10) x100
H: Rounds Scrapped
10
J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical f ailure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planned Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities D11 Operation repeated Development C51 Training
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Grp 4
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
Duration
30 mins 45 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed cap feeder jammed cap feeder spare fetched from Fitter's store
0.827x0.558x0.995x100 =45.9%
H: Rounds Scrapped
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J: Operating Time:
360 mins
Availability :
82.70%
Performance: 45.90%
55.8%
E. 'Machine Losses
Breakdow n losses E11 Sudden mechanical f ailure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Set-up adjustm ent losses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Losses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planned Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities D11 Operation repeated Development C51 Training
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downs: Availability: 0 OEE= 0% Overall Equipment Effeciveness (OEE) Log Sheet (Provided we would have used plant Machine: Month: if it had been up.)
Performance % Right First Time % OEE %
Availability %
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Machine:
Performance % Right First Time %
Month:
Availability %
OEE % When we didnt use it and we didnt want to. I.e. Weekends with no O/T planned
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Golden Rule
Cells will be encouraged to ask What if. What if we did not have to wait for an Fitter? What if we did not have to wait for a spare part? What if we had a breakdown mid morning break and took our break then rather than waiting for the right time? What if the plant is running and we took a break by splitting the shift? What if we developed a Capital Case to replace the plant?
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Date / Shift
19/10/2004
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Grp 4 Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
1 2
End Time
Duration
15 mins 30 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed f eeder jammed f eeder spare fetched from Fitter's store
390/435x100 = 89.7%
F: Total Duration of Lost Time (mins)
D- F 45 mins J divided by D x100
H: Rounds Scrapped
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J: Operating Time:
390 mins
Availability : OEE :
89.70%
Performance: 48.70%
54.6%
E. 'Machine Losses
Breakdow n losse s E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or sof tw are system failure * E14 Misc (please specify) Set-up adjustm ent los ses E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Los ses E61 Machine not stable on start-up
Planne d not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planned Maintenance Activities44 Change process lubricant C21 Scheduled PPM activities Duplication D11 Operation repeated Development C51 Training
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Date / Shift
Main 19/10/2004
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
plant Minutes/Piece
E:Machine Rate:
0.1 minute/item
Event No.
1 2
End Time
Duration
15 mins 30 mins
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
jammed feeder jammed feeder spare f etched from Fitter's store
0.827x0.558x0.995x100 =48.7%
F: Total Duration of Lost Time (mins)
D- F 45 mins J divided by D x100
H: Rounds Scrapped
10
J: Operating Time:
390 mins
Availability : OEE :
89.70%
Performance: 48.70%
54.6%
E. 'Machine Losses
Break dow n los se s E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specif y) Set-up adjustm e nt losse s E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Loss es E61 Machine not stable on start-up
Planne d not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine s D. ' Method Losses Planne d Mainte nance ActivitieC44 Change process lubricant Duplication C21 Scheduled PPM activities Developm ent D11 Operation repeated C51 Training
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Outcome
We can see an improvement of 7% on Machine Availability and an increase of 2.8% on OEE These are small theoretical increases, but they cannot be discounted. Many small gains all add up
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PLEASE PRINT ALL ENTRIES CLEARLY - THANK YOU.
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Grp 4 Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
Duration
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
435/435x100 = 100%
F: Total Duration of Lost Time (mins)
D- F 0 mins J divided by D x100
H: Rounds Scrapped
10
J: Operating Time:
435
Availability : OEE :
100.00%
Performance: 63.50%
63.9%
E. 'Machine Losses
Breakdow n los ses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Se t-up adjustme nt loss es E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Los ses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planne d Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities De ve lopment D11 Operation repeated C51 Training
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PLEASE PRINT ALL ENTRIES CLEARLY - THANK YOU.
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Grp 4 Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
Duration
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
Record shift
H: Rounds Scrapped
10
J: Operating Time:
435
Availability : OEE :
100.00%
Performance: 63.50%
63.9%
E. 'Machine Losses
Breakdow n los ses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Se t-up adjustme nt loss es E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Los ses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planne d Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities De ve lopment D11 Operation repeated C51 Training
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PLEASE PRINT ALL ENTRIES CLEARLY - THANK YOU.
Date / Shift
19/10/04
Store/Product
Rarden case
Operation:
Capping D=B-A-C
Cell:
Grp 4 Minutes/Piece
E:Machine Rate:
0.1 minute/case
Event No.
Duration
Comments/details of Breakdown Losses (including parts used) for codes E11, E12 & E 13.
H: Rounds Scrapped
10
J: Operating Time:
435
Availability : OEE :
100.00%
Performance: 63.50%
63.9%
E. 'Machine Losses
Breakdow n los ses E11 Sudden mechanical failure * E12 Sudden electrical failure * E13 PLC or softw are system failure * E14 Misc (please specify) Se t-up adjustme nt loss es E21 Setting / Adjustments Idling & Minor Stoppages E41 Breakdow n of previous machine E42 Breakdow n of subsequent machine E43 Component jamming / remove & reset Start up Los ses E61 Machine not stable on start-up
Planned not to run C41 5C / 5S Activities C42 Process / Tool Change Over C43 Clean dow n machine C D. ' Method Losses Planne d Maintenance Activities44 Change process lubricant Duplication C21 Scheduled PPM activities De ve lopment D11 Operation repeated C51 Training
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There would be a payback for the capital investment First we need some data show how bad things are
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OEE is:
A tool for Cells to record and then identify where their Manufacturing weaknesses are, and to rectify these by CI Meetings, seeking assistance from Engineering, QA and Finance or other departments where necessary.
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