1. Overall Equipment Effectiveness (OEE)
01-January-2014
Factory Pulse
Logix Automation Systems Pvt. Ltd.

2. Overall Equipment Effectiveness (OEE)
Elements of OEE
OEE
OEE is the way to Measure Effectiveness
How to increase OEE ?
Prime Cause of Production Loss
OEE Calculation
Fundamental Concept of plant Effectiveness
Factory Pulse
Logix Automation Systems Pvt. Ltd.

3. Overall Equipment Effectiveness (OEE)
Overall equipment effectiveness (OEE) is a hierarchy of metrics to evaluate how effectively a manufacturing operation is utilized.
In an ideal factory, equipment would operate 100 percent of the time at 100 percent capacity, with an output of 100 percent good quality.
The difference between the ideal and the actual situation is due to losses. Calculating the overall equipment effectiveness (OEE) rate is a crucial element of any serious commitment to reduce equipment- and process-related wastes.
Factory Pulse
Logix Automation Systems Pvt. Ltd.

4. Elements Of OEE
Inconsistent Timings, Insufficient Skills. Poor Planning & Scheduling, Different methods, Poor Tooling, Poor start up controls, Missing Parts, Insufficient support, Excessive start-up adjustment
Set-up
Breakdown
Availability losses
Performance losses
Quality losses
Lack of Maintenance, Low Operator Interest, Not knowing of problems, Poor Training, Design Problems, Inferior Material
Minor Stoppages
Speed losses
Material not Available, Change over at start/end, Jams/misfeeds/ overloads, Operator Error, Operator Absence
Overall Equipment Effectiveness
Unclear Design Specs., Poor Maintenance History, Incorrect Settings, Poor Training, Speed Deliberately Reduced, Inconsistent Material
Start-up losses
In process losses
Poor Product Changeover, Inconsistent Materials, No start-up check lists, Waiting for Temp. Pressures, Minor adjustments
Environmental Conditions, inconsistent Materials, Process not followed, Poor Calibration, Gauges not calibrated properly etc.
Factory Pulse
Logix Automation Systems Pvt. Ltd.

5. OEE is the way to Measure Effectiveness
OEE is the way to measure how effectively Machine / Equipment hours are used.
Total time
e.g. 480 min. (1 shift)
OEE goes down due to following Losses
Planned
Downtime
- breaks, planned
maintenance, training
Available time
- breakdowns, repairs
- changeover
- adjustment
- start up
Running time
Downtime
Productive time
Performance
Losses
- machine speed
- short stoppages
- lower yield
Effective time
- scrap
- reject
- rework
Quality Losses
Factory Pulse
Logix Automation Systems Pvt. Ltd.

6. Prime Cause of Production Loss
A production line seldom operates at optimum speed. A myriad of reasons or Negative Performance Impacts, mostly in combination, cause losses in productivity and therefore loss of money. These include:
Line Saturation
There is no place for more output from the machine. For example, a filling machine of a bottling line is running at its max. speed.
Equipment Failure
Machines break down, wear out, are not used properly and so on. All ends up in lost production time.
Product changes
During the change over from one product to another the machine settings must be changed, breakdown may occur and speed must be reduced.
Short Stops
For example, a bottle falls down in a bottling machine and the operator picks it up. These short but frequent events can be the reason for major time loss.
Operator Inefficiency
The operators like to have it nice and easy. They run with lower speed in order to guarantee smooth operation.
Factory Pulse
Logix Automation Systems Pvt. Ltd.

7. Prime Cause of Production Loss
External reasons
Sometimes, the production runs out of orders and the machines have to shut down. Or there can be a failure in the electrical power network far away from the factory.
Product Type
Some products are more difficult to make. There are more breakdowns and quality problems.
Speed Losses
For one reason or another, the speed of the machine is not optimum. In order to save costs, someone has purchased cheap but poor quality raw material.
Quality
Although the machine is running, the products are not good enough for the customers. These are the most expensive kinds of losses.
Missing Material
The raw material storage is empty and machines can not produce any more.
Factory Pulse
Logix Automation Systems Pvt. Ltd.

8. Overall Equipment Effectiveness Calculation
Available time - Downtime
OEE (in %) =
Running Efficiency =
Availability
420 min - 80 min
factor 81%
420 min X
Running time - Performance loss
Productive Performance=
Running time
340 min – 70 min =
factor 79.4%
340 min X
Productive time - Quality loss time
Quality =
Productive time
270 min - 20 min =
factor 92.6%
270 min
Overall Equipment Effectiveness
= 59.6%
Factory Pulse
Logix Automation Systems Pvt. Ltd.

9. How to Improve OEE ?
Data collection is the most important action to increase OEE
Collect data for all downtimes
and losses on the machine
Data analysis and
visible measure
Make improvements
visible and implement
Analysis 5 10 15 20 25 30 35
Repair
Changeover
Tool change
Scrap
Minor Stopp. 33 26 16 7 3
Repairs
Autonomous Mainten.
Change over, Adjustm.
Preventive Maintenance
Tool change
Changeover reduction
Minor stoppages
Standardize tooling
Scrap, rework J F M A S O N D
OEE Trend
Target 2003
Improved machine
reliability
Standardisation
Factory Pulse
Logix Automation Systems Pvt. Ltd.

10. Fundamental Concept of Plant Effectiveness
16 Kinds of loss
8 availability losses
5 productivity losses
3 production/ cost losses
– not part of OEE -
Machine Failure
Management losses
Loss of energy
Set up & adjustments
Motion
Die, Jig and tool losses
Tool changes
Line organization
Yield losses
Start-up losses
Logistics
Minor stoppages
Adjustments
Speed Losses
Defects and Rework
Shutdown
Factory Pulse
Logix Automation Systems Pvt. Ltd.

11. For more information on OEE or our other services
Thank You
For more information on OEE or our other services
Logix Automation Systems Pvt. Ltd.
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Factory Pulse
Logix Automation Systems Pvt. Ltd.