OEE Calculate And Loss Analysis

1、OEE Calculate And Loss Analysis Prepared by IE Team Nov-26-2015 Line Utilization Overall Equipment Effectiveness working time Unloading Time 2.3.4.5.6.7.8.9.10.11.12. Loading Time Available Time Planned Downtime Loss Net Operating Time Speed Loss Defect Loss Value Operating Time Lunch Changeovers Lo

2、ss Production Time Calendar Time 1. Legal non working time 13.14. OEE Framework Unplanned Downtime Loss 15. Line Utilization calculation Loading time = Working time Unloading Time Working time = 24 hours/day * 5 days/week * 52weeks/per year = 6,240 hour/per year Line Utilization (LU) measures the ef

3、fectiveness of how a line is used Loading time(including efficiency losses) Working time(24/5/52) Utilization = OEE calculation Example A machine exhibits the following measurements: Availability of 86.7%; Performance is 93.0%; Quality is 95.0%. The OEE is calculated to be OEE = 86.7% 93.0% 95.0% =

4、76.6% OEE = Availability x Performance x Quality Rate Availability Rate = how much time per shift the line is actually running Performance Rate = how well the line did when it was running Quality Rate = how many quality products were produced at the first time Availability Rate= Availability Time Pr

5、oduction Time where Availability Time is the total time of reason code 0 Production time is the time that is planned to operate when production is arranged(exclude lunch) Performance Rate = Net Operating Time Availability Time Actual Output/UPM Availability Time = where UPM is the maximum output per

6、 minute stably attainable by the Bottleneck Quality Rate= Good Output Actual Output where (Good output)= (Actual output) (Total defects) Therefore, OEE= Where (Availability time) + (First C the objects includes area, shift, line, single machine and WO. Remark: 1.OEE calculation by single machine, th

7、e actual output, total defects and production time are calculated by single machine. 2.OEE calculation by line, the actual output, total defects and production time are calculated by line. 3.UPM come from JDE routing. 2. Calendar Time 1. Legal non working time 1. Calendar Time Total number of hours

8、making up the selected date range. 168 hours per week 8,760 hours per year (8,784 during Leap Year) 2. Legal non working time Days not allowed to work due to governmental regulations or contracts Includes: Legal Holiday Weekend 2. Calendar Time 1. Legal non working time 3. Working time Line Utilizat

9、ion working time Unloading Time 3. 4. 5. 6. Loading Time Lunch Total Time Available for Production: Working time =Calendar Time - Legal non working time 4. Unloading Time Time not scheduled for production or related activities due to lack of demand Includes: No-demand Plant shut down due to capacity

10、 reason or No demand situations New equipment IQ/OQ/PQ or Equipment upgrading Factory building construction Major Maintenance or Sanitation Planned maintenance or Sanitation by month, week and day Not related to production schedule Un-sellable Trial/ Rework WO (example: R&D trial) General administra

11、tive Administrative activities(example: fire-drill) Suspend production decided by management Line Utilization working time Unloading Time 3. 4. 5. 6. Loading Time Lunch 5. Loading Time Loading Time = Working Time Unloading Time Example A machine is scheduled to run for an 5 days week. The normal wee

12、k includes a scheduled 1 day shutdown. Loading Time = 5 days 1 day shutdown = 4 days Line Utilization working time Unloading Time 3. 4. 5. 6. Loading Time Lunch 6. Lunch Non-Nut Lunch Time = 40 minutes Nut Lunch Time = 50 minutes Lunch Time more than 40 or 50 minutes will be vest in unplanned Down T

13、ime Line Utilization working time Unloading Time 3. 4. 5. 6. Loading Time Lunch 7. Production Time The time that is planned to operate when production is arranged Production Time = Loading Time - Lunch Time 7. 8.9.10.11. Available Time Planned Downtime Loss Changeovers Loss Production Time Unplanned

14、 Downtime Loss Example A machine is scheduled to run for an 8 h (480 min) shift. The normal shift includes a scheduled 40 min lunch break. Production Time = 480 min 40 min break = 440 min 8. Changeovers Loss Changeover time from SKU to SKU Includes： Setups Adjustments 7. 8.9.10.11. Available Time Pl

15、anned Downtime Loss Changeovers Loss Production Time Unplanned Downtime Loss 9. Planned Downtime Loss The time that equipment is down due to planned activities Includes： Preparation Return material to WH,5S, meeting, shift exchange, clear ground, house keeping The preparation of technical requiremen

16、t Replace label, Replace Tank, Replace the auxiliary material Maintenance in production time Job Rotation Training 7. 8.9.10.11. Available Time Planned Downtime Loss Changeovers Loss Production Time Unplanned Downtime Loss 10. Unplanned Downtime Loss Downtime more than 1 minutes Includes： Equipment

17、Failure Machine breakdown Machine adjustment Material Failure Shortage of Packing of Raw, Packing or other indirect Materials Downtime due to material defect Delay Process delay, Supply delay, QA pass delay, Bus delay Wait for water Lunch time delay (The actual lunch time more than standard lunch ti

18、me ) 7. 8.9.10.11. Available Time Planned Downtime Loss Changeovers Loss Production Time Unplanned Downtime Loss NOTE: 1. Unplanned downtime loss of ATS, WTS and Filter packing line refers to more than 2 minutes of downtime 11. Available Time The time that equipment is available to run Available tim

19、e= Production Time Setup Time Downtime Example A machine is scheduled to run for an 8 h (480 min) shift. The normal shift includes a scheduled 40 min lunch break. The machine undergoes 60 min of unplanned downtime. Production Time = 480 min 40 min break = 440 min Available Time = 440 min production

20、time 0 min setup 60 min downtime = 380 min 7. 8.9.10.11. Available Time Planned Downtime Loss Changeovers Loss Production Time Unplanned Downtime Loss 12. Speed Loss 11.12.13. Available Time Net Operating Time Speed Loss The time that equipment lost relative to its designed speed Includes： Idling an

21、d minor stoppages Stoppage less 1 minutes(ATS, WTS and Filter packing line stoppage less 2 minutes) Reduced speed Time the line operated at less than the standard speed Ramp-up and Ramp-down 12. Speed Loss Added production time due to running below the Standard Speed Standard Speed Ramp-up Minor Sto

22、ps Ramp-down Reduced speed Time 13. Net Operating Time The time that equipment run at ideal cycle time. Ideal cycle time = 60/(UPM) 11.12.13. Available Time Net Operating Time Speed Loss NOTE: 1. UPM is the maximum output stably attainable by the Bottleneck. 2. UPM is maintained by IE Team. 14. Defe

23、ct Loss 13. Net Operating Time Defect Loss Value Operating Time 14.15. Time where un-saleable product was produced Also includes the losses due to quality checks Includes： Scrap The time loss due to scrap Rework The time loss due to rework on line Comment: Defect exclude rework to reuse during produ

24、ction(Finished Goods) ! （exclude HT） 15. Value Operating Time 13. Net running time Defect Loss Value Operating Time 14.15. Value Operating Time is the Std Speed Defect Free Running Time Std Speed = Maximum speed stably attainable by the Bottleneck Defect Free = Saleable Product transferred to the ne

25、xt process Running Time = In this case refers to time production ran at Full Speed and produced Defect Free product OEE Loss The 3 OEE factors are influenced by the 5 Big Losses: Availability rate Changeovers Loss Planned downtime Loss Unplanned downtime Loss 1. Setup 2. Preparation 3.Equipment fail

26、ure 4.Material failure 5.Delay 6. Reduced speed 7. Idling and minor stoppages Speed Quality 8. Scrap 9. Rework Performance rate Quality rate 5 Key Losses OEE Loss=1- OEE% =Changeovers Loss%+Planned Downtime Loss%+Unplanned Downtime Loss% + Speed Loss% + Quality Loss% OEE Loss Calculation Quality Los

27、s% = (Total defects)/(Std UPM)/(Production Time) Changeovers Loss%= (Changeovers Time)/(Production Time) Planned or Unplanned Downtime Loss%= (Planned or Unplanned Downtime )/(Production Time) Speed Loss%= (Speed Loss Time)/(Production Time) Where (Available Time) (Std running time) = Speed Loss Tim

28、e (Actual output)/(Std UPM) = Std running time Std UPM come from JDE routing 3%2%2%4% 10% 15% 13% 17% 20% 25%30% 38% 8% 9% 5% 11% 1% 3% 2% 1% 0% 20% 40% 60% 80% 100% SKU #1SKU #2SKU #3SKU #4 2015.07 OEE Loss SetupPlanned DowntimeUnplanned DowntimeSpeed LossQuality Loss 61% 52%50% 67% 0% 20% 40% 60%

29、80% 100% SKU #1SKU #2SKU #3SKU #4 2015.07 OEE SKU #1SKU #2SKU #3SKU #4 OEE Chart OEE Chart MTBF = Total loading time / No. breakdowns per month MTTR = Total breakdown time / No. breakdowns per month OEE Chart Date：Sep-2-2015 SKU#：CXV4252A Work Center: 30661 Work Oder：49810 UPM：50 Machine data record

30、ed Shift 1 (00:00 8:00) Shift 2 (08:00 16:00) Shift 3 (16:00 24:00) Total Setup (min)39000390 Wait for QA result (min)600060 Preparation (min)0201030 Shift exchange (min)002020 Filler breakdowns (min)020020 Change AMC# (min)001010 House Keeping (min)0101020 Lunch (min)304040110 Output (EA)014,94914,55429,503 Rejects (EA)0100200300