LEAN oee E

Click here to load reader

  • date post

    28-Oct-2014
  • Category

    Documents

  • view

    44
  • download

    1

Embed Size (px)

Transcript of LEAN oee E

LEAN MANUFACTURING

PILLARS OF TPM

OVERALL EQUIPMENT EFFECTIVENESS

BATCH: ERoll Nos: 09M204, 09M210, 09M221

Coordinators E-mail: avinashlage@gmail.com

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

1

LEAN MANUFACTURING

The two top-level metricsOverall 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.

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

2

LEAN MANUFACTURING

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.

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

3

LEAN MANUFACTURING

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

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

4

LEAN MANUFACTURING

Imagine a new car

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

5

LEAN MANUFACTURING

Ideally We want our systems to operate 100% of the time at 100% of our best demonstrated speed producing 100% good quality product/services

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

6

LEAN MANUFACTURING

Reality is Our systems are not ideal its unreasonable to expect to operate all the time at best ever speeds producing nothing but good product/services

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

7

LEAN MANUFACTURING

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, its important they perform efficiently OEE is a metric used in Lean and Six Sigma to indicate how efficiently business systems are performingFaculty: VIJAYANAND.V7-Sep-12COURSE CODE. CLASS. PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

8

LEAN MANUFACTURING

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

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

9

LEAN MANUFACTURING

Availability (Uptime)Availability: A comparison of the potential operating time and the time in which the system is actually making products or providing services.

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

10

LEAN MANUFACTURING

Yield

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

11

LEAN MANUFACTURING

Performance (Utilization or Speed)

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

12

LEAN MANUFACTURING

Overall Equipment/Service Effectiveness (OEE)

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

13

LEAN MANUFACTURING

OEE: How its Calculated OEE = Performance x Availability x Yield

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

14

LEAN MANUFACTURING

The following is an 8 hour shift with two scheduled 15 minute breaks and a 30 minute lunch break during the hypothetical production processTOTAL PEICES SHIFT LENGHT BREAKS LUNCH DOWN TIME IDEAL RUN RATE REJECT PEICES 19,271 8 * 60 = 480 MINUTES 2 * 15 = 30 MINUTES 30 MINUTES 47 MINUTES 60 PIECES PER MINUTE 423 PEICES

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

15

LEAN MANUFACTURING

CALCULATIONVARIABLE PLANNED PROD. TIME OPERATING TIME GOOD PEICES FORMULA Total time shift breaks Planned prod. Time down time Total pieces rejected pieces CALCULATION 480 - 60 420 - 47 19271 - 423 RESULT 420 minutes 373 minutes 18,848 pieces

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

16

LEAN MANUFACTURING

RESULTS0EE FACTOR FORMULA CALCULATION RESULT

AVAILABILTY

Operating time / planned prod. Time(total pieces / operating time) / ideal run rate

373 / 420

0.8881

PERFORMANCE

(19271/373) / 60

0.8611

QUALITY

Good pieces / total pieces 18848 / 19271

0.9780

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

17

LEAN MANUFACTURING

Overall Equipment Effectiveness = 0.8881 * 0.8611 * 0.9780 = 0.748 = 74.8 % For a world class plant,OVERALL OEE AVAILABILITY PERFORMANCE QUALITY 85% 90% 95% 99.9%

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

18

LEAN MANUFACTURING

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

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

19

LEAN MANUFACTURING

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

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

20

LEAN MANUFACTURING

Summary OEE helps maximize throughput efficiency.

It focuses on Performance, Availability, and Yield Before capital expansions, check your OEE!

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

21

LEAN MANUFACTURING

Faculty: VIJAYANAND.V7-Sep-12

COURSE CODE.

CLASS.

PAGE

Department of Mechanical Engineering

08M017

BE: 6M-G2

22