How to Improve OEE?
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What is OEE?
OEE (Overall Equipment Effectiveness) is a significant tool of Lean Manufacturing and TPM (Total Productive Maintenance).
OEE highlights the "major losses" in the manufacturing process to regain "hidden capacity". Improvement of OEE means reduction on losses and improvement on production capacity.
In order to improve OEE, we need to focus on the three factors of the OEE: Availability, Performance, and Quality.
Availability factor represent the stoppage losses such as Breakdowns or Equipment Failures, Changeovers (Setups, Adjustments) and Waits.
Performance factor represent the losses caused by minor stoppages and speed reductions.
Quality factor represent defects/NOKs/rejects/scraps including rework.
World class targets are Availability %90, Performance %95, Quality %99 and as a result OEE %85. These numbers are defined based on practical experience, as minimums for which companies should strive. All of the companies winning the Distinguished Plant Prize, awarded annually in Japan to plants that had successfully implemented TPM, had OEE scores in excess of 85%.
The reality is that most manufacturing companies, even today, have OEE scores closer to 55%. We work with hundreds of manufacturing companies, and we see more companies with OEE scores lower than 45% than companies with OEE scores higher than 75%.
How to improve OEE ?
Improvement activities can be grouped as
1. Fire fighting
2. Fire prevention
In the event of fire we need to immediately take action to extinguish fire. Next action should be to work on how to prevent similar fire.
Instant data help us for fire fighting. If we have speed reduction problem at a machine, we need to know it at the incident moment. We can take action immediately and we can minimize the loss.
To prevent fire, we do 6 sigma projects or kaizen. Excellent plant is not the one which has the fastest/biggest fire fight team.
Another grouping can be as
Perceptual improvements are easy apples which are at the bottom branches of an apple tree. If you are aware of a problem you can solve it or improve it. Most of the perceptual improvement ideas come from the workers themselves, they are less likely to be radically different, and therefore easier to implement. Small improvements are less likely to require major capital investment than major process changes.
Systematical improvements are feed by analysis. For analysis, we need detailed and trusted data.
Tools to help improve OEE
As ProManage we supply powerful tools to help you to improve OEE.
Trusted and Instant Data
The core system is based on automatic and real-time data collection from the machines. We minimize the human dependency on data collection.
In many manufacturing plants, the production data is gathered via forms manually. Managing team found many in consistencies on the reports so they cannot thrust the data. Also forms are collected at the end of the shift and the reports are become available with at least one shift delay.
Trusted data is indispensable for management to make healthy and correct decisions.
Analysis on Thrusted Data
ProManage obtain detailed and trusted data and offer detailed and trusted analysis reports.
ProManage provides a rich variety of analysis reports, which enables you to identify your losses and discover the potentials for systematical improvements. These reports helps to prevent fires.
Visualization Instant Data
Visualization Instant Data feeds perceptual improvements. Nearly all manufacturing plants have operational excellence experts. They are equipped all sorts of needed to do improvements. But when the workforce is not aware of problems, it is not enough. ProManage's Andon / Dashboard solutions provide instant visualization on the shop floor for operators and shift leaders in order to create awareness and improve OEE.
Every manufacturing plant has shift leaders or such responsible to help workers for problems. As an every resource, qualified workforce is limited and cannot deal with every incident. Visualization of instant data helps them to focus on correct area.
Escalation help us for fire fighting. If we have speed reduction problem at a machine, we need to know it at the incident moment. We can take action immediately and we can minimize the loss.
ProManage's automatic escalation shorten the response time to problems and directly results OEE improvement.