Role Of OEE in Lean Manufacturing

1. Role Of OEE in Lean Manufacturing www.downtimecollectionsolutions.com

2. An Overview In the case of lean manufacturing, we focus on excluding non-value-adding activities and waste to reduce complexity and cost.  It provides a foundation for operational excellence by process standardization, worker empowerment and instills a culture of continuous improvement.

3. OEE, a measurement used in Total Productive Maintenance programs, is a metric commonly found in Lean Manufacturing. The OEE metric and Lean process can help manufacturing answer three questions: How fast is the machine when running? How often is the machine available to run? What is the count of acceptable parts made? www.downtimecollectionsolutions.com

4. There are six areas of losses that can affect the OEE and its three components. Breaking down the losses to these categories helps the Lean manufacturing team prioritize improvements.

5. Breakdown Losses This loss falls under the OEE “availability loss” and Lean’s “unplanned stops” – sudden or unexpected equipment downtime that makes the machine less available. Contributing factors may include: •    Major mechanical failures •    Electrical system failures •    Structural failure

6. Set-up & Adjustment Losses These are an availability loss that falls under Lean six big loss of “planned stops”. The degree of loss depends on factors such as: •    Standards process •    Skill-level of operator •    Tooling consistency and quality

7. Idling & Minor Stoppages Production is interrupted by a temporary malfunction or when the machine is idling. This is an OEE performance loss and falls under the Lean “small stops”. Contributing factors include: •    Defective products resulting from a line shutdown •    Operator on other machine or other tasks •    Temporary equipment malfunction

8. Reduced Yield Losses in quality caused by malfunctioning equipment or tooling. An OEE quality loss, the degree of loss depends on factors such as: •    Maintenance of equipment •    Raw Material •    Tooling www.downtimecollectionsolutions.com

9. Process Defects Such defects occur during the stages of production – from machine start-up, warm- up, and “learning phase”. This stage is an OEE quality loss and “production rejects” in the Lean stages. The degree of loss depends on factors such as: •    Maintenance of equipment •    Raw Material •    Tooling •    Operator skill level

10. Reduced Speed Losses This stage refers to the difference in equipment design speed and the actual operating speed. It is an OEE performance loss and a Lean “slow cycles”. Factors include: •    Mechanical problems •    Operator training                                                             •    Risk of making unacceptable parts at higher speeds www.downtimecollectionsolutions.com