Performance

Evaluation &
Incentive
Scheme for
Production
Supervisor
Bombay Rayon Fashions
Limited
07-Aug-13

Losses:
Down Time
Loss
Availability is the ratio of Operating Time to Planned Production
Time (Operating Time is Planned Production Time minus Down Time
Loss).
Calculated as the ratio of Operating Time to Planed Production Time.
100% Availability means the process has been running without any
recorded stops.
Speed Loss
Performance is the ratio of Net Operating Time to Operating Time
(Net Operating Time is Operating Time minus Speed Loss).
Calculated as the ratio of Ideal Cycle Time to Actual Cycle Time.
100% Performance means the process has been consistently running
at its theoretical maximum speed.
Quality Loss
Quality is the ratio of Fully Productive Time to Net Operating Time
(Fully Productive Time is Net Operating Time minus Quality Loss).
Calculated as the ratio of Good Pieces to Total Pieces.
100% Quality means there have been no reject or rework pieces.



0 20 40 60 80 100 120
Quality
Performance
Availabilty
Planned Production Time
Overall Equipment Effectiveness
Productive Time
Losses
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 Assembly
Production Rejects


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 95.33
71.49

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%<
<60% Warning