Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness is the score comprising of
- Availability of the machine,
- Performance of the machine, and
- Quality of the production process.
OEE= Availability x Performance x Quality
- The ideal OEE production score is 100%
- World-class manufacturer score starts at 85% OEE
- Meanwhile the typical manufactures OEE score is 60%
- Manufacturers shorn of TPM or Lean programs have OEE scores that start from 40% score.
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Availability is an OEE measurement for the damage of machine availability. It measures planned and unplanned stops.
This measurement helps improve the uptime of the machine. It agreements with the Equipment Failure as well as Setup and Adjustments.
- Availability= (Scheduled Operating Time – Stop Time) / Scheduled Operating Time
- Planned Operating Time = Accessible Time – breaks
- Stop Time = Equipment Failure time, Setup and alteration time
Performance measures OEE for loss of machine performance. It methods the Cycle Time of the production.
This metric helps recover the cycle time of product manufacturing. It deals with the Idling and Minor stops and Reduced Speed.
- Performance= (Perfect Cycle Time x Total Count) / Run Time
- Total Count = No of product produced
- Ideal Cycle time = Time to make a product
- Run Time = Planned Operating Time – Stop Time
Quality is an OEE measurement for the loss of quality in the process. It measures the first-pass part by the machine. And this metric also helps recover the quality of the machine.
It deals with Process defects and Startup Rejects.
- Quality= Good Count / Total Count
- Good Count = Total no of products created – Defects
- Total Count = No of products produced
Pillars of TPM
The eight pillars of TPM are the techniques used to implement the TPM to improve OEE.
By implementing these techniques, convenience, and performance of the machines improve. And machine defects produced also diminish.
The pillars covered here are:
- Autonomous Maintenance
- Continuous Improvement
- Preventative Maintenance
- Early Management of New Equipment
- Process Quality Management
- Administrative Work
- Education & Training
Autonomous Maintenance means the operator monitors the equipment’s situation and work areas. This process includes that the operator continues and cleans the machine every day.
The Autonomous Maintenance process raises the skill level of the worker since they meet knowledge about the workings of the machine. Also, AM reduces the investment of the organization because it makes the machine reliable. This process also increases the lifetime of the machine through continuous monitoring and maintenance.
Also Read: Six Sigma methodology process improvement
Continuous improvement is also known as Kaizen in Japanese. The concept is based on improving a process that in turn, helps an organization improve quality and productivity. Kaizen is the improvement of activities that run on the PDCA cycle. It comprises
- Analyzing and
- Eliminating NVA in the process.
Kaizen teams are formed with people from various disciplines. A machine’s problems are identified and improved with a Kaizen event. At Kaizen events, employees map the current state of a process and then base their improvement of that system on the desired future state of the system. Teams that use Kaizen start with identifying the root cause of their problems and then try to resolve it.
Planned maintenance is a maintenance activity that precedes the breaking down of a machine. This prevents machine downtime. It’s also called Preventive Maintenance. Team leaders set preventative maintenance tasks schedules, and then assign them to operators.
Early Equipment Management
Early equipment management aims to build a maintenance system in the product design phase itself to drive high competence. EEM helps machines run improved and keep them low maintenance. EEM works like autonomous maintenance.
Process Quality Management
Quality management improves product quality by certifying that a machine detects failure for itself during production. Catching errors early means more dependable production processes and higher product quality.
Training and Education
Training and education provide the knowledge essential to operate the machines to full capacity. The benefit of training and education is that trained operators and managers deliver their duties better. Operators can carry out maintenance activities that would have required a maintenance team.
Office TPM confirms that people carrying out supportive functions appreciate and apply Lean principles in their operations. This process helps implement TPM activities, boosts system effectiveness, and reduces NVA.TPM principles can also be applied as stand-alone techniques to improve the efficiency of supportive functions. Thus, the Pillars of TPM helps to improve the system.
OEE provides the standards for ascertaining the availability, performance, and quality of a machine. A process that’s done by monitoring and eliminating the six big losses. The ultimate goal of an organization is to end all production breakdowns, defects, and delays.