Latest Techniques to improve your
Overall Equipment Effectiveness (OEE), Cycle Time and Plant
Productivity
PARTICIPANTS
Mangers, Engineers who are responsible for: Production Lines & Plant Operations,
Maintenance Planning & Follow Up, Production Planning & Scheduling, Workflow
Studies, Time & Motion Studies
PROGRAM OUTLINE
1. INTRODUCTION
Benefits of measuring Cycle Time, Productivity & OEE
Role of different parties in measuring & analyzing Cycle Time,
Productivity & OEE
Measuring, analyzing and solving problems of Cycle Time, Productivity
& OEE
2. MATERIAL FLOW PRINCIPLES
Basic Definitions
Throughput WIP turn rate Takt Time
Cycle Time Standby Time Active & Passive
Buffer
Work-in-Process Time to re-instate Rebatching
WIP (TTR)
Material Flow Principles:
CLEARING FUNCTION
Conservation of Material
Principle
Capacity Principle
Little's Law LITTLE’S LAW
Variability Principles
Variability Buffering Principle
Batching Principles
Serial Process Batching
Principle
Parallel Process Batching
Principle
3. CYCLE TIME ANALYSIS
Total Cycle Time Concepts
Cycle Time Calculation with a Rework Loop
Cycle Time Analysis: Setup Time - Processing Time - Processing
Times -Waiting Time Analysis
Cycle Time Efficiency Time & Productivity Analysis
Cycle Time Management (CTM) Total Time T
4. PRODUCTIVITY ANALYSIS
Active Time T5 In active T4
Productivity & Operations:
The relation between Slitting Line Up Time T1 Down Time T6 In active T4
Productivity, and: Net Productivity,
Total Cycle Time, Performance Up Time T1 Planned T2 Unplanned T 3 In active T4
Rate, Quality Rate (Quality Yield), Production P P T1 T5
x
Material Yield T otal Productivity =
Time
=
T
=
T1 T5
x
T
Productivity & Production Planning &
Net Productivity
Net Productivity Mechanical Utilization Factor
Utilization Factor
Scheduling: Mechanical
Availability
Availability
The relation between Productivity,
and: Uptime, Non-Scheduled Time, Scheduled Downtime, Utilization
Factor, and Physical Availability
Productivity & Maintenance :
The relation between Productivity and: Mean Time Between Failures
MTBF, Mean Cycles Before Failure MCBF, Mean Time To Repair
(Recovery) MTTR, ……
Productivity & Cost :
The relation between Productivity and different types of Cost: Unit Cost, Hour Cost,
Batch Cost
5. OVERALL EQUIPMENT EFFECTIVENESS (OEE) & SIX BIG LOSSES
OEE = Availability Rate x Performance Rate x Quality Rate
(Yield)
OEE calculation methods
Method 1—Using Nakajima formulas The OEE and the Six Big Losses of TMP
Method 2—Using event time records 1. Equipment Failure and
Breakdowns Availability
Method 3—Using product based calculations 2. Set-ups and Adjustments
World-Class OEE (according to Nakajima) 3. Idling and Minor Stops
4. Reduced Speed Performance
Total Effectiveness Equipment Performance
(TEEP) 5. Reduced Yield
Quality
6. SIX COMPONENTS OF MAINTAINABILITY 6. Scrap
1. Elemental Activities
2. Malfunction Active Repair Time:
Preparation time Part procurement time
Malfunction verification Repair time
time
Fault location time Final malfunction test time
3. Malfunction Repair:
Malfunction active Malfunction
repair time administrative time
4. System Repair Time
5. System Downtime:
System logistic time System repair time
System final test time
6. Total System Downtime is a combination of the distributions of
Initial delay System downtime
7. OPTIMIZING PRODUCTION LINE PERFORMANCE
Effect of variability level on operating Curve
Synchronizing the 4 M’s in production
Determining Optimal Lot-Size
Impact of dispatching rules on Production line performance
Effect of Maintenance Strategy on operating Variability
Operating Curve for different Variability Levels