INTRODUCTION FOR IMPROVING OVERALL EQUIPMENT EFFECTIVENESS (OEE) TOWARDS ZERO EQUIPMENT LOSSES
Overall Equipment Effectiveness (OEE) began to be recognized as a fundamental method for measuring plant performance, OEE is a crucial measure in TPM that tells you how well your equipment is running. It links three elements in one percentage, the time the machine is actually running, the quantity of products the machine is turning out, and the quantity of good output.
Before OEE, people monitored equipment performance through Availability or Downtime. This was acceptable until it was realized that you could have the same downtime for the same piece of equipment over different timeframes yet get a different output.
Overall Equipment Effectiveness (OEE) is a multi-dimensional metric that provides an overall measure of the effectiveness and utilization of a machine or production line, this is performed by multiplying availability by performance and quality, one of the most important KPIs for Industries, it is why measuring and monitoring KPIs is critical to the success of any Industries.
COURSE OBJECTIVES
- Upon completion of this interactive training session, participants will be able to:
- Have a thorough understanding of the practical realities of the OEE measurement process for a range of applications and Industries
- Know some of your options for OEE Software
- Why is OEE a Key Indicator to Measure Lean Manufacturing Performance?
- How can OEE be used as a problem-solving tool?
- What will Sustainable Improvements in OEE give us?
- What are the Key Success Factors and Pitfalls to Avoid?
COURSE CONTENT
Module 1
Introduction to TPM and OEE
- What is TPM?
- TPM Principles
- Why is TPM Important?
- TPM Goals
- TPM Reduces Waste
- TPM Pillars & Activities
- TPM Benefits
Module 2
OEE Understanding Equipment-Related Losses
- What is OEE?
- Three Key elements of OEE
- World Class OEE
- Implication of OEE.
- Why is OEE Important?
- How to calculate OEE?
- Measure Availability
- Measure Performance
- Measure Quality
- OEE and Capacity
- Benchmarking of OEE
- How to improve OEE?
- Benefits of Calculating OEE
- What Affects the OEE Losses?
- Conducting an OEE Loss Analysis
- OEE is a Diagnostic Metric
Module 3
Understanding the 6 Big Losses and how to address their root causes
- Six Big Equipment Losses
- Visualizing OEE and the Six Big Losses
- Setups and adjustment.
- Idling and minor stoppages.
- Speed losses.
- Quality defects and rework.
- Start Up Loss
- Equipment Losses & OEE
- Six Big Losses & Countermeasures
- Strategies for Zero Breakdowns
Module 4
OEE Data Collection: A Traditional Simple Approach
- Collecting Data about OEE
- Clarify Your Purpose for Collecting Data
- Collecting OEE Data
- Basic Tools for Evaluating Data
- Brainstorming to Gather Ideas
- Processing OEE Data
- Measuring OEE
- Reporting OEE Data
- Closing the Feedback Loop
- Practical Tips for Measuring OEE
Module 5
Introduction Autonomous Maintenance AM
- Definition of AM.
- Objectives of AM.
- Concepts of implementing AM.
- Relationship of AM to OEE.
- Describe the activities in OEE-AM (Autonomous Maintenance)
- Develop task transfer list for the operators.
- Periodic review of AM teams’
- Overall benefits of AM in the organization.
Module 6
- Improving OEE on Existing Machinery
- Using Pareto Analysis to Identify What Needs Improvement Most
- Implementing a Quick Changeover to Improve Process Flexibility
- Benefits of Quick Changeover
- Failure States of Equipment
- Benefits of Tracking OEE
- Relationship Between TPM & OEE
Module 7
What is an OEE Dashboard?
- Dashboards for one machine, Dashboards for the whole shop
- Displaying OEE for a single machine
- Displaying OEE for the whole shop
- Why you need an OEE dashboard
- Putting OEE in context
- OEE over time
- OEE with other analytics
- OEE with human-centric data
- Getting Started with OEE Dashboards
- Establish Your OEE Baseline
Module 8
Develop TPM Culture and Implementing Equipment Reliability and Maintenance
Plan continuous improvement activities.
- Measurement tools for performance of OEE.
- Calculating Mean Time between Failures Parameters
- Calculating Mean Time to Repair or Replace
- Calculating Scheduled Downtime
- How to Eliminate Minor Stoppages
- How to Sustain TPM & OEE
- Critical Success Factors
- Evaluating Equipment Conversions
