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OEE (Overall Equipment Effectiveness/Efficiency) Help

8balluk

Starting to get Involved
#1
Hi there,

Ive been asked to set up OEE on a few machines which im more than happy to do. Never done it before and nor as the company.

Having read up on it now for a couple of hours it seems like an impressive tool of which if applied correctly we can definately yield benefit from.

From a newbie in this field the initial issues i can see are:

1. The gathering of the numbers. To me the numbers need to be generated automatically (hence some software package). For instance if i am reliant on operators filling out time sheets telling when and how long the machine is down its destined to fail before it starts.

2. Quality of the product might not be an instant feedback, as we have an inspection department. what happens if the product is made but it sits on a rack for 2 days and only then does it come to light that there is an issue.

Thanks in advance for any advice
c
 

somashekar

Staff member
Super Moderator
#2
1. The gathering of the numbers. To me the numbers need to be generated automatically (hence some software package). For instance if i am reliant on operators filling out time sheets telling when and how long the machine is down its destined to fail before it starts.
I believe that, if the operator is not taken into confidence and made a part of the OEE exercise, its destined to fail sooner than later...
2. Quality of the product might not be an instant feedback, as we have an inspection department. what happens if the product is made but it sits on a rack for 2 days and only then does it come to light that there is an issue.
The focus here is equipment churning out parts / or not and how effectively it is being used or begging to be used, 24 x 7.
That the parts made are good is an other exercise and run concurrently.
 

8balluk

Starting to get Involved
#3
thanks for the reply.

yes i understand that the operator needs to be part of the excercise and will be but from my experience operators filling out forms will die sooner rather than later and the numbers can not be trusted.

concerning my statement about about quality, what you say isnt really answering my question. one of the 3 major catorgories being 'defect losses', i need to understand what the rework and rejects. but if i dont have that number till later whats my way around it.

thanks
 
D

Duy Efeso

#6
Dear 8BALLUK

I have similar issues like you. The workers not fill the losses data as it needs. If they do that, you will see the "gap". Theorically the OEE plus losses must be equal 100%. Then we cross check with them and make some correction actions.

Best regards,

Duy
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#7
Sometimes we over measure and under improve.

I have found the amount of improvement is inversely related to the sophisticaion of the measurement formulas, data collection and reporting methods.

The measure I use is simple: number of manhours/number of units out. (you are paying the operators even if they are doing nothing - for whatever reason) In the end that's the only thing that counts. in my experience, every other refinement of the measure is just obfuscation of where the true problems lie.

sad, but true.
 

Chennaiite

Never-say-die
Trusted
#9
I don't think Quality of the parts produced can be taken out of equation in calculating OEE. In fact, what is effectiveness without Quality?

8balluk,
If the parts are lying in rack for inspection, which I assume is normal for your process, why not measure OEE at an interval that is suitably fixed to accomodate inspection results.
 

somashekar

Staff member
Super Moderator
#10
I don't think Quality of the parts produced can be taken out of equation in calculating OEE. In fact, what is effectiveness without Quality?

8balluk,
If the parts are lying in rack for inspection, which I assume is normal for your process, why not measure OEE at an interval that is suitably fixed to accomodate inspection results.
While quality of the parts is the essence without which there is no effectiveness, the focus in the case of OEE must be machine utilization (meaning it simply churns out acceptable parts) and unlike manpower, the machine is there installed and commissioned to work 24x7x365 days. Optimizing this is the purpose of OEE and it also throws up the non effective time which the management will have to take notice of and plan to feed load.
How much is set-up time and how to reduce set up time, How much is idle time (missed opportunity to get output from the equipment, as it is there begging for load), How to optimize maintenance down time to get maximum equipment uptime = optimum effectiveness ... these must be visible from the OEE.
 
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