Background to the PRIME OEE Manager

PRIMEs 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

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What is in the PRIME OEE Manager system? 1. 2. 2. 3. 4. 5. 6. 7. OEE Data Entry System, with Reports and Graphs Maintenance Management Module, including work control, preventive maintenance and stores management. Downtime Analysis Reports Production and Cost Reports Equipment Failure Analysis & Graphs Tooling Management, including full audit reporting, and overhaul scheduling Production and Cost Reports Failure Mode, Effect & Criticality Assessment Module (for engineering failures)

8.
9.

Root Cause Elimination (RCE) Module

Projects/Modifications Management OEE Reports & Graphs
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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) Scheduled Production Capacity Available Production Capacity

Less Unmanned Shifts = Less Downtime Losses = Less Runrate Losses =

Achieved Throughput

Less Quality Losses =

Effective Operation

Usual Basis For Planned Hours

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:
Present Uptime Quality Efficiency OEE 84% 93% 64% 50% Possible 95% 98% 91% 85% Possible Maintenance Improvement Involvement 11% 5% 27% 35% 40% 30% 40% Maintenance Contribution 4% 2% 11% 14% 1,389,057 1,889,057 3.8

Value of Possible Maintenance-Related Benefit Current Total Cost of Maintenance (Direct + Indirect) Maintenance Cost Escalation Factor

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.

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(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)

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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

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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

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(Please Left-Click to see a typical OEE report)

OEE PERFORMANCE by Week/Cell

Cell Description
Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area Machines Area

Week W/C Date

3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 2/06/2003 9/06/2003 16/06/2003 23/06/2003 30/06/2003 7/07/2003 14/07/2003 21/07/2003 28/07/2003 4/08/2003 11/08/2003 18/08/2003 25/08/2003 1/09/2003

Uptime
76.49% 70.28% 79.31% 75.31% 70.97% 62.43% 77.85% 60.40% 42.96% 47.56% 87.59% 92.14% 83.53% 95.89%

Rate

Quality

OEE
61.16% 48.34% 44.88% 45.77% 32.34% 49.12% 39.25% 33.03% 29.47% 35.84% 56.54% 52.65% 56.02% 55.87%

79.95% 100.00% 68.79% 100.00% 56.59% 100.00% 60.78% 100.00% 45.64% 78.72% 99.86% 99.94%

50.42% 100.00% 54.69% 100.00% 68.59% 100.00% 75.37% 100.00% 64.55% 100.00% 57.15% 100.00% 67.06% 100.00% 58.27% 100.00%

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

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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

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Downtime by Stoppage Code

For operations in the period: 26/05/2003 to 24/08/2003

Summary Downtime by Category

For operations between 26/05/2003 and 20/12/2003

Page 1 of 1

Cell Downtimefor Selected Categories Mag Star Weekly 1

Mag Star 1
Changeover/Set-Up 84.8 29.0 0.0 15.3
0.5 0.0

Equipment

Downtime Category Stoppage Type

Response Dtime Hrs Time

Repair Time

Total Downtime

For Downtime Categories between aa and zz Problem Production Production Production Changeover W/C Date Mech WeekNo Breakdown

Weekly Engineering Uptime Performance Downtime 25.4 0.0 Hrs

Other Reason Shift Production No Production 26/05/2003 3.22 WeekNo Planned W/C Date Shortage of Labour
Engineering Internal Mats For production in the period: Raw 7/07/2003 and 13/07/2003

94.2 30.0 26.7 10.4

94.2 30.0 27.2

Machines Area

10.4 0.8 Hours Planned Eng D/T Hours Eng Uptime 6.0 0.0 7.7 7.7 3.23 13.6 Machines Area 2/06/2003 Lack of Parts 4.0 Packing Team Not Ready 0.0 5.9 5.9 Earned 9/06/2003 3.24 21.7 3.22 26/05/2003 14.84 0.0 100.00% Awaiting QA 2.4 For operations between 26/05/2003 and 7/09/2003 Awaiting QA 0.0 3.4 3.4 Made Returned Lost Hrs 16/06/2003 3.25 15.1 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 Time Total Downtime for Equipment 178.8 23/06/2003 3.26 18.0 Machines Area 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 Ribbon30/06/2003 10CM X 5M3.25 Parts 0 2.5 3.27 20.6 16/06/2003 72.86 13.1 82.06% Mag Star 6000 1 Problems 1.3 7/07/2003 Mon - Thurs 55020Planned RibbonHrs 1.25CM X 1M 2000 0 0.8 Production 0.0 40.4 40.4 7/07/2003 27.4 3.26 Hrs3.28 23/06/2003 72.86 Other MTTR(Hrs) Mechanical3.8 Failure 6.08 Dtime 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 50051 Yellow scissors 16800 60 1.8 Fracture 5.3 95.5% 3.29 15.4 3.27 30/06/2003 70.86 3.8 94.59% Mechanical 4.58 Mag Star 1 525 14/07/2003 23.7 13 40 Mag Star 2 Engineering 0.3 14.4 14.6 Totals for Day 24800 60 8.6 97.7% 3.30 28.9 3.28 7/07/2003 72.86 4.2 94.29% Gasket 4.25 Mag Star 2 525 21/07/2003 12.1 6 87 2.0 Leakage Production Problem 23.8 0.0 No Production Planned 5.1 5.1 28/07/2003 3.31 41.6 3.29 14/07/2003 72.86 2.8 96.23% Hose/Pipe Failures 3.75 Packing Team Not Ready 5.1 5.1 Changeover/Set-Up 18.8 0.0 8/07/2003 Mon - Thurs 55990 Stopcock innards 1480 0 0.9 4/08/2003 3.32 38.2 3.30 21/07/2003 72.86 7.7 89.38% Mech Seal or Gland 3.41 Awaiting QA 0.0 2.6 2.6 16.8 8/07/2003 Mon - Thurs 53100 Size 2 vent ring with end Other Reason 3000 0 2.5 11/08/2003 3.33 9.00.0 3.31 28/07/2003 72.86 1.4 98.06% Fastener Problems 2.50 Internal Raw Mats 1.3 1.3 Mech Breakdown 11.3 8/07/2003 Mon - Thurs 50051 Yellow scissors 23400 0 7.3 18/08/2003 3.34 5.70.0 3.32 4/08/2003 72.86 1.8 97.60% Lubricator Problems 1.58 External Raw Mats 0.5 0.5

Downtime by Fault Type Mean Time Between Downtime Events

Packing Totals for Day Problem 27880 3.33 11/08/2003 Shortage of Labour Parts Problems 3.35 25/08/2003 Totals for Day 16200 Awaiting QA
3.36 3.34

4.1 4.0 2.4 2.0 0.6

Total Downtime for Equipment 72.86 0.0 Chain Problems

72.86 58.02 44.52

0
0

10.7

88.4 100.00% 1.00

100.00%

9/07/2003

Mon - Thurs

50051

Yellow scissors

Mag Star 2 18/08/2003 16200

1/09/2003

0.0 5.1

10/07/2003 10/07/2003

Mon - Thurs Mon - Thurs

56780 50051

Martin seal Yellow scissors

Lack of Parts 1030

2.0 0Chain Problems 5.1 Other Mechanical0.0 Failure

9.23 96.55% 2.33 100.00% 0.58 0.50 39.79

Total 9600
10630
24900

83.8

0 Seal or 0.6 Mech Gland 0 3.0 Mechanical Fracture

Totals for Day

11/07/2003 Friday 50004 Cutdown scissors

0 Time for 3.6 Total Lost Cell:

0 7.8

Totals for Day

24900

7.8

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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 prime00@onetel.com 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