OEE Overall Equipment Effectiveness an important KPI for...
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Copyr i gh t 2015 O SIs o f t , LLC .
Presented by
OEE
Overall Equipment Effectiveness
an important KPI for Operational
Intelligence
Thomas J. Lang
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC . 2
OEE and the usage within BCS
Special application of OEE at Frankfurt site
Benefit
Agenda
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
The meaning of OEE
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OEE (Overall Equipment Effectiveness) is a best practice metric that
identifies the percentage of planned production time that is truly productive.
An OEE score of 100% represents perfect production: manufacturing only
good parts, as fast as possible, with no down time.
Therefore OEE can be also an important number/metric within an MES
system, for global and local Management.
Copyright: Thomas J. Lang
100% (Perfect) 90% (World Class) 80% (Typical) 60% (Low)
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Copyr i gh t 2015 O SIs o f t , LLC .
The classical OEE definition is mainly used by the
global management with a focus on ROI
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Maximum
OutputMax. performance
of production line
Equipment, personal,
material, logistics
available
Required
quality
Overall
Equipment
Effectiveness (OEE)
= Availability x Performance x Quality
KPI for the return on
invested capital
calendar year
percentage of the
real losses
Rate of losses generated
by downtimes
Downtimes
missing personal
disruption of plant
no order
Missing material
Missing energy or
other supplies, etc.
Changeover times
Produced quantity/
planned quantity
Target quantity
means the theoretical
plant quantity (or the
ever shown best
quantity)
Quality is the criteria for
in spec product
and calculated as:
Quality =
Good Pieces / Total Pieces
=
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The KPI OEE is explicitly important for capital
intensive industries
Business sector:
Services
Retail business
Banks
Automotive
Machine building
industry
.
.
Chemical
industry
Leverage to increase ROI:
Maximum usage (productivity) of
invested capital
KPI: OEE
Ca
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Imp
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Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
Within a 24/7 production - the global OEE definition can
be used on a production site
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OEE is the identical definition
Demand is real high, the production plant
runs continously without any stops
Quality: First pass rate
OEE is product from the factors availability,
performance and quality
Availability: 365 d - 24 h
Perfomance: Performance takes into account
Speed Loss or maximum production
Quality: First pass rate
2009 Agamus Consult - All rights reserved
090515_OEE_Steuerung.PPT6
Die technische Kapazitt orientiert sich an den technischen Mglichkeiten der Anlage
Definition technische Kapazitt
DefinitionDefinition
Die technische Kapazitt ist die vorgegebene Menge fr eine Anlagengruppe oder einen Fertigungsbereich und ...
orientiert sich an den technischen Mglichkeiten der Anlage weil eine zu hohe technische Kapazitt zu berhhter Abnutzung und damit zu hohen Kosten fhren kann.
... ist an den Engpassanlagen der Anlagenkette orientiert: GA 50: Verseifer; ACM: Destillation
... ist bezogen auf den Tag um den Bezug zum Abrechnungsmonat herzustellen
... kann sich ndern durch nderungen in der Anlage bzw. dem Verfahren
GA 50: 25 to/Tag
Die technische Kapazitt ist die vorgegebene Menge fr eine Anlagengruppe oder einen Fertigungsbereich und ...
orientiert sich an den technischen Mglichkeiten der Anlage weil eine zu hohe technische Kapazitt zu berhhter Abnutzung und damit zu hohen Kosten fhren kann.
... ist an den Engpassanlagen der Anlagenkette orientiert: GA 50: Verseifer; ACM: Destillation
... ist bezogen auf den Tag um den Bezug zum Abrechnungsmonat herzustellen
... kann sich ndern durch nderungen in der Anlage bzw. dem Verfahren
GA 50: 25 to/Tag
Technische Kapazitt
Technische Kapazitt
Plan-Taktzeit
Ist-Menge
: Ist-Taktzeit
technischeKapazitt
VerfgbarkeitVerfgbarkeitLeistungs -
faktor
Leistungs -faktor
Qualitt-faktor
Qualitt-faktor
x x =Anlagen-
effizienz(AE)
Anlagen-effizienz
(AE)
OEE- definition by BCS Global Production time 7 days 24 h
=
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
. but BCS at Frankfurt site made a further development
to maximize the local benefit of the KPI OEE
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The classical OEE-definition is a good definition for
plants producing within 24 h/7 d, in a 1- to 3- shift
production this definition isnt perfect
In the chemical industry the separation into the
availability- and the performance -factor is for a
continuous running plant often very difficult
The OEE-factors availability and performance dont
deliver any information about the reasons for the
downtime (continuous improvement isnt possible)
In our special case no sufficient information about
the performance and the weaknesses were delivered
by this KPI
Weak points of OEE from a local view
Enhancement
of the OEE
required
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
The separation of availability and performance losses is difficult
to use for best practice in a continuous operated plant
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Classification of an availability and performance (yield) loss shown in a real time example (e.g. chemical plant)
100 % OEE
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Copyr i gh t 2015 O SIs o f t , LLC .
on the other hand a local definition has to be adopted
to the site specific situation
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Equipment
Staff
Material
Utilities, services
Rework to be done
Unrecoverable, out-of-spec
product
Types of losses classical OEE for Produktion
can be influenced
Intentional slowdown
Market / product demand and
higher forces
cant be
influenced
max. achievable
OEE rate for a 1-
shift production
can be
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Copyr i gh t 2015 O SIs o f t , LLC .
In contrast to the traditional OEE-definition losses
will be adopted to the origin (company)
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lossess
OEE
(global)
losses
SEE
(site)
SEE = SEEtechnical + SEELogistics + SEEproduktion + SEEothers
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Copyr i gh t 2015 O SIs o f t , LLC .
Result: OEE/SEE continously improves
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Adaption of 100 % definition by 10%
96 %
79 %
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
As shown above, a measurable additional
value could be achieved by increasing the
productivity e.g. production increase from
e.g. 79% to 96 %
Solution(s) Results and Benefits
OEE/SEE a beneficial tool to improve the production
Business ChallengesOEE is a mixture of a corporate approach
and helps to identify process goals helps
to increase yield, improve efficiency and
effectiveness
OEE/SEE is a Business solution, which
can show you a potential weakness in your production assets/process
OEE (Overall Equipment Effectiveness) is a best practices metric thatidentifies the percentage of planned production time that is trulyproductive. An OEE score of 100% represents perfect production,manufacturing only good parts, as fast as possible, with no down time.
OEE is useful as both a benchmark and a baseline.
As a benchmark it can be used to compare the performance of a givenproduction asset to industry standards, to similar in-house assets, or toresults for different shifts working on the same asset.
As a baseline it can be used to track progress over time in eliminatingwaste from a given production asset.
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Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
Thomas J. Lang
Consultant (former BayerCS AG)
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Consultant (former BayerCS AG)
Copyright: Thomas J. Lang
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Copyr i gh t 2015 O SIs o f t , LLC .
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