As we talked about in the last blog, a big factor of OEE losses is downtime. We will now go more in depth into causes and solutions in tracking and reducing your plants downtime.
If you have not already started using OEE (Overall Equipment Effectiveness) to evaluate your plant, you may want to start considering it. OEE uses logical equations to track your plants losses machine by machine. This includes downtime, speed, and quality. Downtime can be scheduled or unscheduled. This post will go over the benefits and cost savings of OEE.
Whether you’re a small shop or a major manufacturing company, every process benefits from a close analytical study of efficiency. But what about the methodology for examining and improving efficiency in your process? KPIs, or Key Performance Indicators, are an established and successful way of evaluating a shop or factory’s performance. There are three key elements to an effective KPI journey.
If you’re already gathering data, where is it going?
In many cases, production data gets lumped into raw data dumps that offer a basic overview of averages over time. While useful, this information often gathers dust as a stack of printouts or files idling on the server. That same storage may suffer from different extremes: too much raw information overwhelming the capacity for parsing it into usable feedback, or too little, collected infrequently or irregularly.
What is Overall Equipment Effectiveness, or OEE?
The simple equation is Production Rate x Availability x Quality. But the real answer is self-consciousness.
Every company seems to want to improve their business with Lean Manufacturing ideology. The idea of reducing unnecessary waste, improving efficiency and quality is the pathway to succeeding in a highly competitive industry. The best way to evaluate a factory’s performance is by measuring the Overall Equipment Effectiveness (OEE). Although you can calculate OEE by hand it requires a lot of work from each team member. Calculating OEE manually can take weeks to analyze, distracts operators from working so they can record information, and can be affected by human error. However, automated solutions make it possible for OEE data to be collected instantly and accurately.
What is OEE?
Overall Equipment Effectiveness (OEE) is, in simple terms, a way to determine the efficiency of equipment in a manufacturing environment. A few key metrics are used to calculate OEE and inform manufacturers as to how the different pieces of equipment are performing.
Availability = Operating Time / Planned Production Time
Performance = Ideal Cycle Time / (Operating Time / Total Pieces)
Quality = Good Pieces / Total Pieces
OEE = Availability x Performance x Quality
This allows managers to make key decisions in order to increase or maintain efficiency, thus saving time and money. For this reason, it is obviously beneficial to monitor and increase OEE.
When making improvements to a system, you have to look at historical data to identify where the weak spots are. You can’t make anything more efficient or improve quality if you don’t know what needs the most attention. It’s a simple and obvious concept, but it brings about the question of where to get the information to best read the current system. Patterns over time can point to particular areas that could stand to be changed, but more current information can illuminate more specific details. This is where Key Performance Indicators come in. Key Performance Indicators, or KPIs, are an essential part of any production system.
HMIs, or Human Machine Interfaces, are a crucial aspect of any productive plant. They are the easiest way to display data and up-to-date analysis of information from the plant’s machines and equipment. HMIs have a range of functions that help operators control the line more efficiently and more safely. On the floor, these tools can pull together charts and graphs, make suggestions, and sound alarms for a number of machines. Since the introduction of HMIs, they have made leaps and bounds, always progressing towards something more powerful, more straight forward, and more helpful.
OEE stands for Overall Equipment Effectiveness. It is a measure in percentage of how well a production machine is utilized over a period of time. A rating of 100% means that a machine never breaks down, never runs slower than target time, and never produces a bad part. Although this is the goal, no machine is perfect, but having a way to measure how a machine performs gives us a way to determine whether changes to a machine are beneficial or not.