Wonderware Interactive Webinar Series

Helping you see more clearly

Understanding OEERichard Stone

Lean Manufacturing Manager

Why look at OEE

► “Make more for less” or

“Make the same in less time”

► Efficiency & Capacity gains

► A measure for driving improvements

► Monitors Downtime, Speed and quality

► OEE has a direct effect on your Labour, Materials and Energy costs

What is OEE

Shift Time

Planned Production (A)

Actual Production Time (B)

Output at theoretical speed (C)

Actual units produced (D)

Total Pieces Produced (E)

Good Parts (F)

Planned Stoppage

Unplanned Downtime

Speed / Minor stoppages

Shift Time

Value Adding Time Wasted Processing time

OEE = Availability (B/A) * Performance (D/C) * Quality (F/E)

Quality Losses

What is OEETwo main aspects of each OEE component…

Availability : Actual vs. planned production time

1. Equipment setup

2. Equipment breakdowns

Performance : How process is running compared to its target rate

1. Speed reductions

2. Minor stoppages (“micro-stops”)

Quality : Percentage of first-pass quality

1. Setup yield

2. Production yield

Is OEE a burden on you ?

► Generating a number is great but what are you going to do with it.

► We see manual OEE systems which are fantastic in introducing the concept ,but end up becoming a burden on the company.

► Collecting of Data

► Processing of data

► Do we actually make improvements

Why SolutionsPT Solutions

► Real-time plant connected

► Wonderware has the shop floor data collection technology

► Allows you to react to production issues as they occur

► Use data to act as incentive systems for operators

► Collection of all the downtime reasons accurately and to the level of detail you need

► Collection of performance losses. These are often bigger than availability losses. Become accepted working practice.

► Efficient data collection and reporting

► Realtime and manual data entry

Plant Visibility for Continuous Improvement

► Why do we do OEE? part of a CI program, Lean, Kaizen, 6 Sigma.

Define

Measure

AnalyseImprove

Control

6σ

Plan

DOCheck

Act

6 Sigma Kaizen

Creating a circle of improvement

► What is OEE actually doing

► It transforms data into information

Production Facility

Paper based data collection

Data, Data, Data

Production Reports

Data to information

Removing Waste from the process

Production Facility

Historical Production Reports

Continuous Improvement

Real-time Visibility

Wasteful Processes

OEE Supporting 6 Sigma

► 6 Sigma uses data

► Define

► Measure

► Analysis

► Improve

► Control

= Information

OEE Supporting Kaizen & Lean

► Kaizen = Japanese for Continuous Improvement

► Adding value and removing waste

► Support Kaizen Events / Blitz

► Lean Manufacturing

► Helps you understand your Value Stream. Cycle times, transfer times, effects of raw material & labour

The company culture

► For OEE to be affective all levels of the company must understand and use it.

► Finance for cost control

► Energy team for efficiency improvements

► Maintenance - downtime and TPM planning

► Quality - Yield levels, rejects in the process, giveaway.

► .....

Simple Operator Displays

providing real-time feedback

OEE Solution – Pace Maker

See what you want

“Zero Footprint” Web-Based Reporting

►Flexible Report Templates▪ OEE & Downtime

▪ Production Event Summary

►Extensible▪ Easily create report

instances for specific users

►Wired for Analysis▪ Drill through by passing

parameters

▪ Determine root cause of production problems

Drill Down Reports

Benefits of OEE

- Are you looking to reduce production costs

- Are you losing production capacity due to excessive rework

- Is waste effecting your yield levels and effecting your output

- Would it help if you were able to find your production bottlenecks

- Can you accurately see the effect change over's are having on production output

- Can you really see the effect that minor stoppages are having on your performance

- When you start a new production run can you get up to speed as quick as you want

- Do some of your operators manage to get better production rates and would you like to know why

- If you could improve your line efficiency would it affect your energy usage

- Are your lines stopping because raw materials aren’t being delivered to the lines ontime

- Would you like to know your most common downtimes are so you can drive an effective TPM program

Future Events

► Next Webinar

► QI Analyst

“Reduce the variability in the output of your processes” – 14th Oct.

► Lean Manufacturing Seminar

“Streamlining your operations” - 3rd Nov.

www.wonderware.co.uk

www.wonderware.ie

► Q&A Session

Powering intelligent plant decisions in real time.