Overall

Equipment
Efficiency
SIS -TPM- AM
OVERALL EQUIPMENT EFFICIENCY

OEE was used to measure the

performance of the TPM process.

It is a tool to measure
Equipment Availability (uptime),
Work Efficiency ( speed ratio )
& Quality Products Rate.
SIS- TPM-AM
 Points to Note for OEE Measurement

A measurement tool of TPM activity performance.

Minimum one bottleneck machine or equipment in the
production line to be selected & analyzed.

The measurement must consider the 7 major losses.

Recorder must clear & understand the definition of the

7 losses.
Daily record & monitoring is necessary & continuous
Minimum target setting for OEE is 80%

SIS- TPM- AM
 7 Major Losses Effecting Equipment Efficiency

• Failure losses
• Setting up / Adjustment losses
• Cutting tool change losses
• Start-up losses
• Minor stoppage / Idling losses
• Speed losses
• Defect / Rework losses
SIS-TPM- AM
 Problems Facing OEE Measurement

• The definition of each of the 7 major losses is not

clear & understood.
• A measuring system has been not been established
• Although a measuring system has been established,
accurate data is insufficient.
• The structure of losses is not understood.
• Solving the problem not done by sequential logic.
• The bottleneck process has not been identified.
SIS-TPM- AM
 Areas We Can Improve Through OEE

• Understanding the structure of 7 major losses

• Checking contribution ratio of each problem
• Monitor & improve bottleneck process / machine
• Listing of impeding factors & countermeasures
• Improvement of process capacity index
• Reduction of machine intermittent stoppage
• Quality improvement & assurance

SIS-TPM- AM
 MEASUREING OF OEE (1) ---- FORMULA

Overall (1) (2) (3) Quality

Equipment = Availability X Performance X Performance
Efficiency Rate Rate Rate

SIS-TPM- AM
 MEASURING OF OEE (2) ---- Loading Time
Loading Time = Daily working time - planned down time

8.00 am ~ 5.18pm --> 9 hrs 19 mins

Lunch Time --> 30 mins
Daily working Time Daily working time --> 8 hrs 48 mins
(8.00 am to 5.18pm)

Planned no prod. --> 180 mins

Tea-Break --> 20 mins
Planned Morning exercise --> 10 mins
Morning briefing --> 10 mins
Loading Time Down
Monthly maintenance --> 0 mins
Time Daily maintenance --> 10 mins
planned down time --> 230 mins

Loading Time = (528 - 230 mins) = 298 mins

SIS-TPM-AM
 MEASURING OF OEE (3) --- Operating Time(Availability Rate)

(1) Availability Rate = Loading Time - Downtime X 100%

Loading Time
Losses Events Mins
Loading Time ( 298 mins ) Part supply / Quality problem 8
Failure Sorting out of parts 15
1 Losses Troubleshooting 10
M/C downtime 0
Frequency of M/C NG 2
Operating Time Top-up coolant / oil 0
Set-up Data collection 0
2 & Adj. Other stn. Model change 10
Losses Model change 5
Process monitoring 0
Tooling Change
Down 3 Change cutting tool / insert 0
Losses

Time 4 Set-up Losses Start-up preparation 15

Minor Stoppage
5 No Compressoe supply 5
Losses
6 Defect Losses Rework time 10
80

Availability Rate = ( 298 - 80 ) ÷ 298 X 100% = 73.2%

SIS-TPM- AM
MEASURING OF OEE (4) --- Net Operating Time(Performance Rate)
Std. Cycle time X Output
(2) Performance Rate = X 100%
Operation Time
Capacity (By Calculation) :
Operating Time (218 mins)
Formula : Operating Time ÷ Std. Cycle Time
If, Operating Time : 218 mins

Cycle Time : 13.2 sec / unit

Net Operating Time 0.22 min / unit

Therefore : 218 mins ÷ 0.22mins

= 990 units

Capacity (Actual condition) :

Speed Actual Prod. Line Achieved : 800mins
Losses
Speed Loss :

(418mins) Speed lose = (990 - 800 ) X 0.22

= 41.8 mins

Performance Rate = ( 0.22 X 800 ) ÷ 218 X 100% = 80.7%

SIS-TPM- AM
MEASURING OF OEE (5) --- Defect Losses (Quality Products Rate)

Prod. Volume - Defective Volume

(3) Performance Rate = X 100%
Prod. Volume

Production
Volume

Defect
Losses
Production Volume : 800 units / day
Production Reject : 20 units / day

Quality Performance Rate = ( 800 -20 ) ÷ 800 X 100% = 97.5%

SIS-TPM-AM
MEASURING OF OEE (6)

Overall (1) (2) (3) Quality

Equipment = Availability X Performance X Performance
Efficiency Rate Rate Rate

OEE = Availability X Performance X Quality Products X 100%

= 0.732 X 0.807 X 0.975 X 100%
= 57.6%

SIS-TPM- AM
 OVERALL EQUIPMENT EFFICIENCY CALCULATION
7 Major Losses Calculation
1) Equipment Failure Loading Time - down Time X 100%
Availability Rate =
Loading Time
Loading Time
(Example)
2) Setup & adjustment Availability Rate = (298 - 80 ) mins X 100%
298 mins
= 73.2%
Downtime
looses
Operating 3) Cutting Tool change Std. Cycle Prod.
Time Performance Rate =
Time Volume X 100%
Net Operating Time
4) Start-up (Example)
0.23 mins X 800 units
Performance Rate = X 100%
218 mins
Net
Losses
Speed

= 80.7%
Operating
5) Minor Stoppage
Time Product Defect
X
Volume Units X 100%
Quality Product Rate =
Defect Losses

Product Volume
6) Speed
Valuable (Example)
(800 - 20) units X 100%
Operating Quality Product Rate =
800 units
Time
7) Defects & Rework = 97.5%

OEE
OEE==0.732
0.732XX0.807
0.807XX0.975
0.975==0.576
0.576 (57.6%)
(57.6%)
SIS-TPM- AM