LEAN oee E
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Transcript of LEAN oee E
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 1
PILLARS OF TPM
OVERALL EQUIPMENT EFFECTIVENESS
BATCH: E
Roll Nos: 09M204, 09M210, 09M221
Coordinator’s E-mail: [email protected]
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 2
The two top-level metrics
• Overall equipment effectiveness (OEE) and total effective equipment performance (TEEP) are two closely related measurements that report the overall utilization of facilities, time and material for manufacturing operations. These top view metrics directly indicate the gap between actual and ideal performance.
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 3
• Overall equipment effectiveness quantifies how well a manufacturing unit performs relative to its designed capacity, during the periods when it is scheduled to run.
• Total effective equipment performance (TEEP) measures OEE against calendar hours, i.e.: 24 hours per day, 365 days per year.
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 4
Goals• Learn about OEE and how to use it to improve
– overall efficiency– throughput, and quality in a plant, office, or service environment
– Learn how to use OEE to• Improve real-time efficiencies• Evaluate capital expenditures• Compare one operation to another
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 5
Imagine a new car
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 6
Ideally……
• We want our systems to operate 100% of the time at 100% of our best demonstrated speed producing 100% good quality product/services
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 7
Reality is …
• Our systems are not ideal … it’s unreasonable to expect to operate all the time at best ever speeds producing nothing but good product/services
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 8
Why is OEE so important?
• Companies make money by adding value to materials and services to make products customers want
• As most companies use machines, people, and production lines to add value to their products, it’s important they perform efficiently
• OEE is a metric used in Lean and Six Sigma to indicate how efficiently business systems are performing
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 9
• OEE helps us to maximize
1. Performance … speed and/or utilization
2. Availability … uptime
3. Yield … quality
• Allows us to compare processes across plants, divisions, offices, and companies
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 10
Availability (Uptime)Availability: A comparison of the potential operating time and the time in which the system is actually making products or providing services.
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 11
Yield
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 12
Performance (Utilization or Speed)
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 13
Overall Equipment/Service Effectiveness (OEE)
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 14
OEE: How it’s Calculated
• OEE = Performance x Availability x Yield
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2
• The following is an 8 hour shift with two scheduled 15 minute breaks and a 30 minute lunch break during the hypothetical production process
15
TOTAL PEICES 19,271
SHIFT LENGHT 8 * 60 = 480 MINUTES
BREAKS 2 * 15 = 30 MINUTES
LUNCH 30 MINUTES
DOWN TIME 47 MINUTES
IDEAL RUN RATE 60 PIECES PER MINUTE
REJECT PEICES 423 PEICES
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2
CALCULATION
VARIABLE FORMULA CALCULATION RESULT
PLANNED PROD. TIME
Total time – shift breaks
480 - 60 420 minutes
OPERATING TIME Planned prod. Time – down time
420 - 47 373 minutes
GOOD PEICES Total pieces – rejected pieces
19271 - 423 18,848 pieces
16
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 17
RESULTS
0EE FACTOR FORMULA CALCULATION RESULT
AVAILABILTY Operating time / planned prod. Time
373 / 420 0.8881
PERFORMANCE (total pieces / operating time) / ideal run rate
(19271/373) / 60 0.8611
QUALITY Good pieces / total pieces
18848 / 19271 0.9780
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 18
Overall Equipment Effectiveness = 0.8881 * 0.8611 * 0.9780 = 0.748
= 74.8 %
For a world class plant,
OVERALL OEE 85%
AVAILABILITY 90%
PERFORMANCE 95%
QUALITY 99.9%
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 19
• This is a good plant, yet the OEE calculation gives us insight that even better results might be achieved by attacking performance and availability issues
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 20
Improving OEE• Our approach should incorporate quantitative
expectations, milestones, and a firm schedule for improvement.
• A proven, effective way of quickly improving OEE is through a kaizen improvement event … the kaizen is also a great way to also increase worker/supervisor buy-in
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 21
Summary• OEE helps maximize throughput efficiency.
• It focuses on Performance, Availability, and Yield
• Before capital expansions, check your OEE!
COURSE CODE. PAGE
LEAN MANUFACTURING
Department of Mechanical EngineeringFaculty: VIJAYANAND.VApr 7, 2023 08M017
CLASS.
BE: 6M-G2 22
Thank you