Transcript The PRIME 'OEE Manager'

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)
What is in the PRIME “OEE Manager” system?
1.
OEE Data Entry System, with Reports and Graphs
2.
Maintenance Management Module, including work control,
preventive maintenance and stores management.
2.
Downtime Analysis Reports
3.
Production and Cost Reports
4.
Equipment Failure Analysis & Graphs
5.
Tooling Management, including full audit reporting, and
overhaul scheduling
6.
Production and Cost Reports
7.
Failure Mode, Effect & Criticality Assessment Module (for
engineering failures)
8.
9.
Root Cause Elimination (RCE) Module
Projects/Modifications Management OEE Reports &
Graphs
(Please Left-Click when ready to move to the next slide)
What is OEE?
“OEE” stands for “OVERALL EQUIPMENT EFFECTIVENESS”
= % Uptime x % Efficiency x % Quality
Uptime =
Efficiency
Quality
Planned Operating Time - (Downtime + Setup Time)
Planned Operating Time
=
=
Amount Produced
.
Run Time x Standard Production Rate
Amount Produced - Amount of Defects/Rework
Amount Produced
(Please Left-Click when ready to move to the next slide)
A Model for OEE
Possible Shift Hours (“Factory Open”)
Scheduled Production Capacity
Available Production Capacity
Achieved Throughput
Less Unmanned Shifts =
Less Downtime Losses =
Less Runrate Losses =
Less Quality Losses =
Effective Operation
Good Quality Product
(Please Left-Click when ready to move to the next slide)
Usual
Basis
For
Planned
Hours
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
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:
Possible
Maintenance
Improvement Involvement
Maintenance
Contribution
Present
Possible
Uptime
84%
95%
11%
40%
4%
Quality
93%
98%
5%
30%
2%
Efficiency
64%
91%
27%
40%
11%
OEE
50%
85%
35%
14%
Value of Possible Maintenance-Related Benefit
£1,389,057
Current Total Cost of Maintenance (Direct + Indirect)
£1,889,057
Maintenance Cost Escalation Factor
3.8
Maintenance is usually 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)
(Please Left-Click when ready to see details of “OEE Manager”)
• On logging on to “OEE Manager”, you are offered the Selection Menu.
Users can run “OEE Manager” in an integrated manner, or operate any of
the modules in standalone mode.
(Please left-click your mouse)
(Please Left-Click when ready to look at the System Navigator)
• The System Navigator offers a schematic look at how the modules are
related. You can move to any module from this view, or go directly from the
Selection Menu.
(Please left-click your mouse)
(Please Left-Click when ready to go to the OEE Management Menu options)
•The OEE Management Menu comprises a data entry section, and a number
of sets of reports and charts.
(Please left-click your mouse)
(Please Left-Click when ready to move to the next slide)
All Data Entries
use Drop-Down
boxes
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)
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)
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
(Please Left-Click when ready to move to the next slide)
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)
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)
OEE PERFORMANCE by Week/Cell
Cell Description
Week W/C Date
Uptime
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)
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)
(Please Left-Click when ready to move to the next slide)
There are a suite of reports for the following:
• 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)
Downtime by Stoppage Code
Summary Downtime by Category
Page 1 of 1
For operations between 26/05/2003 and 20/12/2003
For operations in the period: 26/05/2003 to 24/08/2003
Downtime
Category
Stoppage
Type
Equipment
Response
D’time
Hrs Time
Repair Time
Cell Downtimefor Selected Categories
Mag StarWeekly
1
For
Downtime
Categories betweenChangeover/Set-Up
aa and zz
84.8
Mag
Star 1
W/C Date
WeekNo
Downtime
Production
Production Problem
29.0 0.0 Hrs
Engineering
Uptime
Production
Changeover
Machines Weekly
Area
Mech
BreakdownPerformance
25.4 0.0
Total Downtime
94.2
94.2
30.0
30.0
Engineering
26.7
27.2
26/05/2003
3.22
0.80.5
Other
Reason
15.3
No Production Planned
0.0
10.4
10.4
2/06/2003
13.6Hours
WeekNo
W/C
Date Planned
Eng D/T Hours
Eng Uptime
Shortage3.23
of Labour
6.0
Internal
Matsand 13/07/2003
0.0
7.7
7.7
For production in the
period: Raw
7/07/2003
3.24
21.7
Machines Area 9/06/2003
Lack
of Parts
4.0
Packing Team Not
Ready
0.0
5.9
5.9
Earned
16/06/2003
3.25
15.1
3.2226/05/2003
26/05/2003
14.84
0.0
100.00%
Awaiting
QA
For operations
between
and
7/09/2003 2.4
Awaiting
QA
0.0
3.4
3.4
Made
Returned
Lost
Hrs
23/06/2003
3.26
18.0
3.23
2/06/2003
58.02
1.3
97.71%
For downtime events in the period:
26/05/2003
and
20/12/2003
Packing
Problem
2.1
Fault
Type
Total Lost
Total Downtime for
Equipment
178.8Time
Machines Area
30/06/2003
3.27
20.6
3.24
9/06/2003
72.86
0.0
100.00%
PPM
Work
1.8
Machines
Area
MTBD = Mean Time between Downtime Events
MTTR = Mean Time to Repair
7/07/2003 Mag
Mon - Star
Thurs2
55124
Ribbon7/07/2003
10CM X 5M3.25Parts3.28
0
2.5
27.4
16/06/2003
72.86
13.1
82.06%
Mag
Star 6000
1
Problems
1.3
7/07/2003 Mon - Thurs
55020Planned
Ribbon14/07/2003
1.25CM
X
1M
2000
0
0.8
Production
0.0
40.4
40.4
15.4
3.26 Hrs3.29
23/06/2003
72.86 Other MTTR(Hrs)
Mechanical3.8
Failure
6.08
Hrs D’time
No.B'downs
MTBD(Hrs)
Eng.Uptime 94.85%
Total
172.1
Production
Changeover
0.0
18.9
18.9
7/07/2003 Mon - Thurs
Yellow
scissors
16800
60 1.8 Fracture
5.3 95.5%
3.30
28.9
3.27
30/06/2003
70.86
3.8
94.59%
Mechanical
4.58
Mag Star 150051
525 21/07/2003
23.7
13
40
Mag Star 2
Engineering
0.3
14.4
14.6
Totals
for Day3.31
60
8.6 97.7%
41.6
3.28
7/07/2003
72.86
4.2
94.29%
Gasket
4.25
Mag Star 2
525 28/07/2003
12.1
624800
87
2.0 Leakage
Production
Problem
23.8 0.0
No Production
Planned
5.1
5.1
4/08/20033.29
3.32
38.2
14/07/2003
72.86
2.8
96.23%
Hose/Pipe Failures
3.75
PackingChangeover/Set-Up
Team Not Ready
5.10.9
5.1
18.8 0.0
8/07/2003 Mon - Thurs
55990
Stopcock innards
1480
0
11/08/2003
3.33
9.00.0
3.30
21/07/2003
72.86
7.7
89.38%
Mech Seal or
Gland
3.412.6
Awaiting
QA
2.6
16.8
8/07/2003 Mon - Thurs
53100
Size 2 vent ring with end Other Reason3000
0
2.5
18/08/2003
3.34
5.70.0
3.31
28/07/2003
72.86
1.4
98.06%
Fastener Problems
2.501.3
Internal
Raw Mats
1.3
Shift Production
Downtime by Fault Type
Mean Time Between Downtime Events
8/07/2003
Mon - Thurs
50051
Yellow scissors
23400
Mech Breakdown
3.32Raw Mats
4/08/2003
External
Packing
Totals for
Day Problem
27880
3.33
11/08/2003
Shortage of Labour
9/07/2003
Mon - Thurs
50051
Yellow scissors
3.34
Mag
Star 216200
18/08/2003
Parts Problems
3.35
25/08/2003
Totals
for Day
16200
Awaiting QA
3.36
10/07/2003
Mon - Thurs
56780
Martin seal
10/07/2003
Mon - Thurs
50051
Yellow scissors
Totals for Day
11/07/2003
Friday
50004
1/09/2003
Lack of Parts1030
Cutdown scissors
Totals for Day
Total9600
10630
11.3
72.86
0.0
0
7.3
0
0.0
5.1
1.8
Lubricator Problems
0.5
4.1
0
10.7
Total DowntimeChain
for Equipment
72.86
0.0
Problems
4.0
72.86
2.4
58.02
2.0
44.52
0.6
83.8
2.0
0Chain Problems
5.1
Other Mechanical0.0
Failure
97.60%
1.580.5
88.4
100.00%
1.00
100.00%
9.23
96.55%
2.33
100.00%
0 Seal or 0.6
Mech
Gland
0
3.0
Mechanical
Fracture
0.58
0 Time for3.6
Total Lost
Cell:
39.79
24900
0
7.8
24900
0
7.8
0.50
(Please Left-Click when ready to view the next report, or move to the next slide)
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)
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 fullyfunctional 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