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PROMOTING RELIABILITY IMPROVEMENT in MANUFACTURING EQUIPMENT - PowerPoint PPT Presentation


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Background to the PRIME “OEE Manager”. PRIME’s main activity is to work with manufacturing companies to assist them in improving equipment performance The best measure for machine performance is OEE (Overall Equipment Effectiveness)

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Background to the prime oee manager l.jpg
Background to the PRIME “OEE Manager”

  • PRIME’s main activity is to work with manufacturing companies to assist them in improving equipment performance

  • The best measure for machine performance is OEE (Overall Equipment Effectiveness)

  • PRIME was unable to find a simple set of tools that would measure OEE performance, present the results at both strategic and operational levels, provide an effective means to drive and manage a continuous improvement programme, and provide tools for managing a maintenance function in a manufacturing business (ie CMMS functionality)

  • The PRIME “OEE Manager” was designed to fill the gap that exists for a simple-to-use, fully-functioning piece of software that would carry out all of these functions. It is based on Microsoft Access 2000 and can, therefore, be extended and modified by individual users to meet their precise needs

(Please Left-Click when ready to move to the next slide)


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What is in the PRIME “OEE Manager” system?

  • OEE Data Entry System, with Reports and Graphs

  • Maintenance Management Module, including work control, preventive maintenance and stores management.

  • Downtime Analysis Reports

  • Production and Cost Reports

  • Equipment Failure Analysis & Graphs

  • Tooling Management, including full audit reporting, and overhaul scheduling

  • Production and Cost Reports

  • Failure Mode, Effect & Criticality Assessment Module (for engineering failures)

  • Root Cause Elimination (RCE) Module

  • Projects/Modifications Management OEE Reports & Graphs

(Please Left-Click when ready to move to the next slide)


Oee stands for overall equipment effectiveness l.jpg

What is OEE?

“OEE” stands for “OVERALL EQUIPMENT EFFECTIVENESS”

= % Uptime x % Efficiency x % Quality

Uptime = Planned Operating Time - (Downtime + Setup Time)

Planned Operating Time

Efficiency = Amount Produced .

Run Time x Standard Production Rate

Quality = Amount Produced - Amount of Defects/Rework

Amount Produced

(Please Left-Click when ready to move to the next slide)


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A Model for OEE

Possible Shift Hours (“Factory Open”)

Less Unmanned Shifts =

Scheduled Production Capacity

Less Downtime Losses =

Available Production Capacity

Less Runrate Losses =

Achieved Throughput

Less Quality Losses =

Usual

Basis

For

Planned

Hours

Effective Operation

Good Quality Product

(Please Left-Click when ready to move to the next slide)


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Why use OEE to measure performance ?

  • OEE incorporates the 3 primary areas of performance loss

    • Loss of equipment availability through all causes

      (eg setup, breakdown, lack of labour, materials etc)

    • Loss through rework or reject

    • Loss through operational inefficiency, startup & shutdown procedures, slow running, minor delays etc

  • Integrates the performance of plant with the performance of people

  • Is multi-factorial, therefore supports a ‘trade-off’ approach to performance improvement initiatives

  • Provides a strategic level view of factory performance for senior management as well as cell level performance for line management

  • Provides a common set of numbers, from Senior Management to line operative

  • Provides a common focus for objectives setting in all manufacturing disciplines (production, engineering, logistics, quality)

  • Is used by virtually all ‘world class’ companies

  • Provides one element of a ‘performance-balanced scorecard’ of KPIs

  • (Please Left-Click when ready to move to the next slide)


    Some typical facts about oee and maintenance l.jpg
    Some Typical Facts About OEE and Maintenance

    Assume a typical SME with an annual manufacturing cost of £5M, an annual maintenance cost of £500k and an OEE level of 50%

    Assume that the constituents of the OEE performance are as below:

    Maintenance isusually responsible for <40% of all downtime losses

    Engineering Downtime usually represents < 20% of all equipment losses

    (Please Left-Click when ready to move to the next slide)



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    (Please Left-Click when ready to look at the System Navigator)


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    (Please Left-Click when ready to go to the OEE Management Menu options)


    Slide10 l.jpg

    (Please Left-Click when ready to move to the next slide)


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    All Data Entries use Drop-Down boxes a number of sets of reports and charts.

    There are 2 screen variants for entering downtime – by event time (shown) or by duration.

    (Please Left-Click when ready to move to the next slide)


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    At each point where a batch of parts has been made, or at the end of each shift, the throughput is entered. This is the total amount manufactured, including reject/waste.

    (Please Left-Click when ready to move to the next slide)


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    When parts are rejected, or committed for rework, this data needs to be entered in the system

    (Please Left-Click when ready to move to the next slide)


    Users can set up abbreviated menus for operator and craftsmen data entry l.jpg
    Users can set up abbreviated menus for operator and craftsmen data entry

    (Please Left-Click when ready to move to the next slide)


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    THIS IS ALL OF THE DATA REQUIRED TO SUPPORT THE GENERATION OF OEE REPORTS, AND TO CARRY OUT CONTINUOUS IMPROVEMENT.

    WE WILL FIRST LOOK AT SOME TYPICAL REPORTS FROM THE SYSTEM

    (Please Left-Click when ready to view the OEE Reports menu)


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    There is a top level Strategic Performance Report that presents top level data for Senior Management.

    The next level of data is based on daily, weekly or monthly views of OEE, Uptime, Throughput or Quality Performance.

    The next slide shows the standard OEE Reports Menu, followed by a typical Weekly OEE report

    (Please Left-Click to see the OEE Reports Menu)

    (Please Left-Click to see a typical OEE report)


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    OEE PERFORMANCE by Week/Cell presents top level data for Senior Management.

    Cell DescriptionWeek W/C DateUptime Rate Quality OEE

    Machines Area 3.23 2/06/2003 76.49% 79.95% 100.00% 61.16%

    Machines Area 3.24 9/06/2003 70.28% 68.79% 100.00% 48.34%

    Machines Area 3.25 16/06/2003 79.31% 56.59% 100.00% 44.88%

    Machines Area 3.26 23/06/2003 75.31% 60.78% 100.00% 45.77%

    Machines Area 3.27 30/06/2003 70.97% 45.64% 99.86% 32.34%

    Machines Area 3.28 7/07/2003 62.43% 78.72% 99.94% 49.12%

    Machines Area 3.29 14/07/2003 77.85% 50.42% 100.00% 39.25%

    Machines Area 3.30 21/07/2003 60.40% 54.69% 100.00% 33.03%

    Machines Area 3.31 28/07/2003 42.96% 68.59% 100.00% 29.47%

    Machines Area 3.32 4/08/2003 47.56% 75.37% 100.00% 35.84%

    Machines Area 3.33 11/08/2003 87.59% 64.55% 100.00% 56.54%

    Machines Area 3.34 18/08/2003 92.14% 57.15% 100.00% 52.65%

    Machines Area 3.35 25/08/2003 83.53% 67.06% 100.00% 56.02%

    Machines Area 3.36 1/09/2003 95.89% 58.27% 100.00% 55.87%

    This is only one of a range of different reports

    (Please Left-Click when ready to move to the next slide)


    Slide18 l.jpg

    The Uptime, Throughput and Quality reports have a similar layout but show more detail.

    The same information can be available in graphical form, that can be either viewed on screen, or printed.

    The slide shows the standard Graphs Menu, followed by typical Weekly OEE Graphs and Weekly Loss Charts

    (Please Left-Click when ready to view the Graphs menu)

    (Please Left-Click when ready to view the charts)



    Slide20 l.jpg

    • There are a suite of reports for the following: layout but show more detail.

    • Downtime Reports, presented in either summary or detail

    • Engineering Reports, again in summary or detail form, that provide analysis of fault types, fault causes, MTBF, Response Time ratios etc

    • Production Reports, presenting summaries and detail of production and reject quantities by shift, day or week.

    • Reports for Cost of Downtime and Cost of Failure

    (Please Left-Click when ready to view some typical reports)


    Slide21 l.jpg

    Downtime by Stoppage Code layout but show more detail.

    For operations in the period: 26/05/2003 to 24/08/2003

    Stoppage TypeD’time Hrs

    Mag Star 1

    Changeover/Set-Up84.8

    Production Problem29.0

    Mech Breakdown25.4

    Other Reason15.3

    Shortage of Labour6.0

    Lack of Parts4.0

    Awaiting QA2.4

    Packing Problem2.1

    PPM Work1.8

    Parts Problems1.3

    Total172.1

    Mag Star 2

    Production Problem23.8

    Changeover/Set-Up18.8

    Other Reason16.8

    Mech Breakdown11.3

    Packing Problem4.1

    Shortage of Labour4.0

    Parts Problems2.4

    Awaiting QA2.0

    Lack of Parts0.6

    Total83.8

    Weekly Cell Downtimefor Selected Categories

    For Downtime Categories between aa and zz

    W/C DateWeekNoDowntime Hrs

    Machines Area

    26/05/20033.220.8

    2/06/20033.2313.6

    9/06/20033.2421.7

    16/06/20033.2515.1

    23/06/20033.2618.0

    30/06/20033.2720.6

    7/07/20033.2827.4

    14/07/20033.2915.4

    21/07/20033.3028.9

    28/07/20033.3141.6

    4/08/20033.3238.2

    11/08/20033.339.0

    18/08/20033.345.7

    Weekly Engineering Uptime Performance

    WeekNoW/C DatePlanned HoursEng D/T HoursEng Uptime

    Machines Area

    3.2226/05/200314.840.0100.00%

    3.232/06/200358.021.397.71%

    3.249/06/200372.860.0100.00%

    3.2516/06/200372.8613.182.06%

    3.2623/06/200372.863.894.85%

    3.2730/06/200370.863.894.59%

    3.287/07/200372.864.294.29%

    3.2914/07/200372.862.896.23%

    3.3021/07/200372.867.789.38%

    3.3128/07/200372.861.498.06%

    3.324/08/200372.861.897.60%

    3.3311/08/200372.860.0100.00%

    3.3418/08/200372.860.0100.00%

    3.3525/08/200358.022.096.55%

    3.361/09/200344.520.0100.00%

    Downtime by Fault Type

    For operations between 26/05/2003 and 7/09/2003

    Fault TypeTotal Lost Time

    Machines Area

    Mag Star 1

    Other Mechanical Failure6.08

    Mechanical Fracture4.58

    Gasket Leakage4.25

    Hose/Pipe Failures3.75

    Mech Seal or Gland 3.41

    Fastener Problems2.50

    Lubricator Problems1.58

    Chain Problems1.00

    Mag Star 2

    Chain Problems9.23

    Other Mechanical Failure2.33

    Mech Seal or Gland 0.58

    Mechanical Fracture0.50

    Total Lost Time for Cell:39.79

    Mean Time Between Downtime Events

    For downtime events in the period: 26/05/2003 and 20/12/2003

    MTBD = Mean Time between Downtime Events MTTR = Mean Time to Repair

    Planned HrsD’time HrsNo.B'downsMTBD(Hrs)MTTR(Hrs)Eng.Uptime

    Mag Star 152523.713401.895.5%

    Mag Star 252512.16872.097.7%

    (Please Left-Click when ready to view the next report, or move to the next slide)


    Slide22 l.jpg

    There is also a range of operational reports covering production performance, equipment slow-running, production and maintenance costs, and operator & craftsmen efficiency, etc.

    The PRIME “OEE Manager” also incorporates all of the tools required to manage an engineering workload, and implement continuous improvement to achieve high levels of equipment performance. These additional, standard features comprise:

    Work Order Management

    Preventive Maintenance Scheduling

    Management of Maintenance Spares

    Tooling Management

    Failure Mode, Effect and Criticality Assessment

    (Designed specifically for Maintenance operations)

    Root Cause Elimination

    Management of Modifications and small Projects

    Any of these sub-systems can be run in isolation of the OEE features (eg a client can use the work order and PPM management features alone, or only the FMEA module etc).

    For more information about these system features, select the “Key Features” tab in one of the OEE web pages

    (Please Left-Click when ready to move to the next slide)


    Slide23 l.jpg

    This short presentation has given you a very brief insight into the PRIME OEE Manager system.

    The PRIME “OEE Manager” is available free of charge to any PRIME client

    You can obtain an onsite demonstration of the software, or a fully-functional demonstration disc by contacting Frank Chambers by e-mail on “[email protected]” or by phone on 044 (0)191 2364150

    I hope that you have found the presentation informative.

    On the next mouse click you will exit the presentation


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