The PRIME OEE Manager by yaofenjin

VIEWS: 7 PAGES: 23

									             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.        Root Cause Elimination (RCE) Module
9.      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 =     Planned Operating Time - (Downtime + Setup Time)
                          Planned Operating Time


 Efficiency   =                Amount Produced            .
                      Run Time x Standard Production Rate


 Quality      =    Amount Produced - Amount of Defects/Rework
                            Amount Produced


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                          A Model for OEE


Possible Shift Hours (“Factory Open”)        Less Unmanned Shifts =


      Scheduled Production Capacity          Less Downtime Losses =

             Available Production Capacity      Less Runrate Losses =


                   Achieved Throughput         Less Quality Losses =     Usual
                                                                         Basis
                                                                          For
                                                                        Planned
                                                                         Hours
                                    Effective Operation

                                    Good Quality Product




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             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        Maintenance
              Present    Possible
                                    Improvement Involvement        Contribution
 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


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(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.

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                                                       All Data Entries
                                                       use Drop-Down
                                                            boxes




                                              There are 2 screen variants
                                              for entering downtime – by
                                               event time (shown) or by
                                                       duration.



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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.




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When parts are rejected, or committed for rework, this

        data needs to be entered in the system




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Users can set up abbreviated menus for operator and craftsmen data entry




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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)
                                                            Summary Downtime by Category                                                         Page 1 of 1
  Downtime by Stoppage Code                                     For operations between 26/05/2003 and 20/12/2003
  For operations in the period: 26/05/2003 to 24/08/2003
                  Equipment                                Stoppage Type
                                                     Downtime Category                   D’time Hrs Time
                                                                                          Response                Repair Time     Total Downtime
  Mag StarWeekly Cell Downtimefor Selected Categories
          1
              For Downtime Categories between aa and zz
                Mag Star 1                   Changeover/Set-Up     84.8
                                             Production Problem Downtime Hrs
                                       W/C Date    WeekNo
                                             Production            29.0 0.0                                           94.2                94.2
              Machines Weekly Engineering Uptime Performance
                       Area        Production Changeover
                                            Mech Breakdown 25.4 0.0                                                   30.0                30.0
                                               26/05/2003 Other Reason
                                                           Engineering 3.22                 0.80.5
                                                                                         15.3
                                                                                                                    26.7                 27.2
                                                 Shift Production
                                                     No Production Planned
                                                2/06/2003 WeekNo 3.23 Date Planned Hours   13.60.0                  10.4                 10.4
                                                             Shortage W/Cof Labour        6.0                  Eng D/T Hours      Eng Uptime
                                                        Internal 7/07/2003 and
                                    For production in the period: Raw Mats 13/07/2003          0.0                  7.7                   7.7
                          Machines Area 9/06/2003
                             Downtime by Fault Type                    3.24
                                                                    Lack of Parts          21.7
                                                                                          4.0 0.0
                                                   Packing Team Not Ready                                           5.9                   5.9
                      Mean Time Between Downtime Events
                                               16/06/2003              3.25
                                                                         26/05/2003
                                                              3.22 Awaiting QA
                                  For operations between 26/05/2003 and 7/09/2003 2.4 0.0
                                                           Awaiting QA
                                                                                Made
                                                                                           15.1
                                                                                            14.84
                                                                                           Returned      Lost
                                                                                                                   Earned
                                                                                                                     0.0
                                                                                                                    3.4
                                                                                                                     Hrs
                                                                                                                                    100.00%
                                                                                                                                          3.4
                                                                       3.26
                                               23/06/2003Packing 2/06/2003
                                                              3.23
                  For downtime events in the period: 26/05/2003 and 20/12/2003
                                                                          Problem          18.0 Downtime for Equipment
                                                                                            58.02
                                                                                          2.1Total                   1.3
                                                                                                                Fault Type           97.71% Time
                                                                                                                                Total Lost
                                                                                                                                        178.8
   Machines Area                               30/06/2003
                                  Machines Area 3.24Events9/06/2003    3.27 Work
                                                                        PPM                20.6
                                                                                            72.86
                                                                                          1.8                        0.0            100.00%
                  MTBD = Mean Time between Downtime                              MTTR = Mean Time to Repair
              Mon Thurs
    7/07/2003 Mag- Star 2      55124                                   3.28
                                         Ribbon7/07/2003 PartsMag Star 6000
                                                 10CM X 5M    3.25       16/06/2003
                                                                         Problems1         27.4
                                                                                            72.86
                                                                                          1.3                0      13.1
                                                                                                                       2.5           82.06%
    7/07/2003 Mon - Thurs          Planned14/07/2003
                               55020             1.25CM XProduction No.B'downs 172.10.0 Other MTTR(Hrs)0.8
                                         RibbonHrs D’time Hrs 23/06/2003
                                                              3.26
                                                             1M        3.29Total   2000    15.4
                                                                                         MTBD(Hrs) Mechanical3.8
                                                                                            72.86            0      40.4Eng.Uptime 94.85%
                                                                                                                      Failure            40.4
                                                                                                                                       6.08
                                          525 21/07/2003               3.30                28.9
    7/07/2003 Mon - Thurs Star 1
                      Mag      50051                Production Changeover 13
                                         Yellow scissors      3.27
                                                              23.7       30/06/2003
                                                                                  16800        0.0
                                                                                            70.86
                                                                                               40           60 1.8  18.9
                                                                                                                     3.8
                                                                                                                       5.3 95.5%
                                                                                                       Mechanical Fracture               18.9
                                                                                                                                     94.59%
                                                                                                                                       4.58
  Mag Star 2                                               Engineering                         0.3
                      Mag Star 2          525 28/07/2003for Day 7/07/2003
                                                        Totals3.28
                                                              12.1     3.31      24800
                                                                                 6         41.6
                                                                                            72.86
                                                                                               87           60 2.0 14.4
                                                                                                                     4.2
                                                                                                                       8.6 97.7%
                                                                                                             Gasket Leakage
                                                                                                                                         14.6
                                                                                                                                     94.29%
                                                                                                                                       4.25
                                                            Production Problem
                                                     No Production Planned               23.8 0.0                   5.1                   5.1
                                                4/08/2003     3.29     3.32
                                                                         14/07/2003        38.2
                                                                                            72.86                    2.8
                                                                                                         Hose/Pipe Failures          96.23%
                                                                                                                                       3.75
    8/07/2003 Mon - Thurs      55990     Stopcock innards Changeover/Set-Up
                                                   Packing Team Not Ready          1480  18.8 0.0            0      5.10.9                5.1
                                               11/08/2003     3.30     3.33
                                                                         21/07/2003         9.00.0
                                                                                            72.86                    7.7
                                                                                                        Mech Seal or Gland           89.38%
                                                                                                                                       3.41
    8/07/2003 Mon - Thurs      53100                       Awaiting QA Reason
                                         Size 2 vent ring with end Other           3000  16.8                0      2.62.5                2.6
                                               18/08/2003 Raw Mats
                                                              3.31
                                                        Internal       3.34
                                                                         28/07/2003         5.70.0
                                                                                            72.86                    1.4
                                                                                                         Fastener Problems
                                                                                                                    1.3              98.06%
                                                                                                                                       2.50
                                                                                                                                          1.3
      8/07/2003   Mon - Thurs      50051    Yellow scissors    Mech Breakdown  23400       11.3               0          7.3
                                                              3.32     4/08/2003
                                                         External Raw Mats                   72.86
                                                                                                0.0                 1.8
                                                                                                        Lubricator Problems
                                                                                                                    0.5               97.60%
                                                                                                                                        1.58
                                                                                                                                           0.5
                                                           Totals Packing Problem
                                                                  for Day         27880     4.1            0         10.7
                                                               3.33       11/08/2003                                0.0
                                                                                              72.86 Downtime for Equipment
                                                                                               Total        Chain Problems            100.00%
                                                                                                                                          88.4
                                                                                                                                        1.00
                                                               Shortage of Labour           4.0
      9/07/2003   Mon - Thurs      50051    Yellow scissors    3.34    Mag Star 2
                                                                        18/08/2003
                                                                                16200        72.86            0        0.0
                                                                                                                         5.1          100.00%
                                                                    Parts Problems          2.4
                                                           Totals for Day 25/08/2003
                                                               3.35
                                                                       Awaiting QA16200      58.02
                                                                                            2.0              0Chain Problems
                                                                                                                      2.0
                                                                                                                        5.1             9.23
                                                                                                                                      96.55%
                                                               3.36         1/09/2003        44.52                     Failure
                                                                                                      Other Mechanical0.0               2.33
                                                                                                                                      100.00%
     10/07/2003   Mon - Thurs      56780    Martin seal               Lack of Parts
                                                                                  1030      0.6               0
                                                                                                           Mech Seal or 0.6
                                                                                                                        Gland           0.58
     10/07/2003   Mon - Thurs      50051    Yellow scissors                   Total
                                                                                  9600     83.8               0         3.0
                                                                                                           Mechanical Fracture          0.50
                                                           Totals for Day          10630              Total Lost Time for Cell:
                                                                                                              0         3.6            39.79

     11/07/2003   Friday           50004    Cutdown scissors                       24900                      0          7.8
                                                           Totals for Day          24900                      0          7.8


(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

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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 fully-
functional demonstration disc by contacting Frank Chambers by e-mail on
        “prime00@onetel.com” or by phone on 044 (0)191 2364150

        I hope that you have found the presentation informative.

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