OVERALL EQUIPMENT EFFICIENCY

INTRODUCTION FOR OVERALL EQUIPMENT EFFICIENCY

Current manufacturing organizations heavily depend on their equipment productivity for achieving their PQCDSM. Profit and loss of a company directly depends on how well the company manage and utilize their assets to the fullest. Are we getting the full efficiency?  this is the big question that every manufacturing head is left to ponder with many organizations depend on lowest down time as the mark of good productivity. Are the down time indices measure efficiency? Down time only measures the time taken for repair and do not reflect equipment reliability. Down time itself is reactive and not proactive.

COURSE OBJECTIVE

To enhance the participants knowledge and understanding on:

• Contribution of equipment to overall productivity.
• How to measure true equipment efficiency.
• What are the 8 major losses of equipment.
• How to calculate OEE the right way.
• What is MTBF, MTTR, MTBA, AV, PE, ROQ.
• How to achieve maximum equipment efficiency.
• Key strategies for improvement.

COURSE CONTENT

Module 1 :  Equipment efficiency in manufacturing

• Changing equipment dependence.
• The three cultures of maintenance.
• Contribution of breakdowns to co$$$$ t.
• Why equipments must run efficient.
• Introduction on TPM concepts.
• The 16 major manufacturing losses.

Module 2 :  TPM ‘s 8 major equipment losses.

• Scheduled down time
• Breakdown losses.
• Setup and adjustment losses.
• Cutting blade losses.
• Startup losses.
• Minor stoppages.
• Speed losses.
• Defect & rework losses.

Module 3 :  Measure overall equipment efficiency 

• TPM’ s ultimate tool for measuring equipment efficiency.
• Understanding manufacturing time structure.
• Constituents of planned / unplanned down time.
• Availability.
• Performance efficiency
• Rate of quality.
• Overall equipment efficiency formula.

Team activity 1: Compute OEE for selected line 

Module 4 :  Improving availability

• Why equipments breakdown.
• Measuring equipment breakdown. (MTBF, MTTR)
• Breakdown improvement strategy.
• Causes of setup time losses.
• Improving setup and changeover

Team activity 2 : Calculate MTBF, MTTR for selected line.

Module 5 :  Improving performance efficiency.

• Measuring minor stoppages.
• Improving minor stoppages.
• Measuring speed losses.
• Strategies for speed improvement.

Team activity 3: calculate MTBA, speed losses.

Module 6 :  Improving rate of quality.

• What is rate of quality
• Measuring rate of quality.
• Strategies for reducing defects.

Team activity : calculate quality losses.

Module 7 : Proactive maintenance strategies.

• Autonomous maintenance.
• Scheduled planned maintenance.
• Predictive maintenance.
• Poka yoke.
• Discard maintenance.
• On-going continuous improvement (Kaizen)