We’ve discussed OEE before. As a quick reminder, overall equipment effectiveness (OEE) is used to help manufacturers notice a problem in their operations, identify which percentage of manufacturing time is actually productive, and fix it while giving them a standardized gauge for tracking progress. When you’re measuring your OEE, remember that the goal is for continuous improvement.
But there are several factors that can be impacting your OEE – whether you know it or not. What are some of these factors? Read on for the answer!
OEE is a powerful figure, providing a lot of information in one number. As a result, there are multiple ways OEE is used to measure manufacturing productivity. It can significantly maximize production when calculated and interpreted correctly. Further, it is commonly used as a benchmark to compare any given production to industry standards, in-house equipment, or other shifts working on the same piece of equipment. According to Reliable Plant, standard OEE benchmarks include the following:
While OEE is a great tool for managers, it can also have a significant impact on employees working the plant floor. Plant floor metrics can include:
Other important terms that often come up when discussing OEE include:
When implementing an OEE program into your operations, the biggest goal should be reducing or eliminating the most common causes of machine- or equipment-based productivity, also known as the six big losses. These six losses are categorized according to the three main OEE categories: availability, performance, and quality.
1. Equipment Failure: unplanned downtime results when equipment does not run when it is scheduled for production. Unplanned maintenance shops, machine breakdowns, and tooling failure are common examples.
2. Setup and Adjustments: changeovers, planned maintenance, machine and tooling adjustments, setup/warmup time, and inspections can all result in production downtime.
1. Idling and Minor Stops: also known as small stops, idling and minor stops occur when equipment stops for a short period of time. These stops can be caused by jams, wrong settings, flow obstructions or cleaning and are usually resolved by the operator.
2. Reduced Speed: also known as slow cycles, reduced speed occurs when equipment runs at speeds slower than the ideal cycle time (the fastest possible time). Common causes of reduced speed include worn out or poorly maintained equipment due to poor lubrication practices, substandard materials, and bad environmental conditions.
1. Process Defects: this term refers to any defective part manufacturer during stable production, including parts that can be reworked and scrapped parts. Common reasons for process defects include incorrect machine settings and equipment or operator errors.
2. Reduced Yield: this term relates to defective parts make from startup until stable production is achieved. Similar to process defects, this can also mean scrapped parts and parts that cannot be reworked. Reduced yield most often occurs after changeovers, during machine warmups, and incorrect settings.
According to Automation World, when used correctly, OEE can provide visibility into the root of plant problems, allowing you to identify your potential losses and understand where plants are falling short. The following are some examples of plants using OEE data to improve availability and performance:
Clearly, whether you choose to use OEE for machines, stations, lines or all three, it’s one of those necessary basic tools that can help you improve production short and long term.
Manufacturers face a multitude of balancing acts: produce more while spending less, create customized products but use standard processes, reduce technology debt while reducing time to market. Finding this balance is challenging.
We’re here to help, with the expertise and experience to provide new ideas and insights. We take a customer-first approach to everything we do, analyzing your pain points and business objectives to co-create a solution custom fit for you. Want to learn more about how we can help you? Contact us today!
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