01-OEE-Kobetsu

KobetsuKaizen®Stand041KobetsuKaizen®KobetsuKaizen®Stand042KobetsuKAIZEN®KobetsuKaizen®IndividualImprovementsWhyisahighOEEimportantforcompanies?CalculationoftheOEEVisualizationoftheOEEintheshopfloorDefinitionOverallEquipmentEfficiencyTargetBreakdownStructureoflossesProblemsolvingPLSKaizenBoard16TypesofLossesKobetsuKaizen®Stand043ProcessLossesObjective:ImprovementandProcessControlthroughtheZero-Defect-Principle5ProductivityLosses3ProductionLossesMachinefailurelossesSetup&adjustingToolchangeStart-uplossesMinorstoppagesSpeedLossesDefectandReworkShutdownManagementlossesMotionLineorganizationLogisticAdjustments8AvailabilityLossesLossofenergyDie,JigandtoollossesYieldlosses16TypesofLossKobetsuKaizen®Stand044OverallEquipmentEfficiencyTheOEEisacriteriaformeasuringtheefficiencyofmachineryandequipment.OEE=OverallEquipmentEffectivenessObjective:ImprovementandProcessControlthroughtheZero-Defect-Principle5ProductivityLosses3ProductionLossesMachinefailurelossesSetup&adjustingToolchangeStart-uplossesMinorstoppagesSpeedLossesDefectandReworkShutdownManagementlossesMotionLineorganizationLogisticAdjustments8AvailabilityLossesLossofenergyDie,JigandtoollossesYieldlosses16TypesofLossKobetsuKaizen®Stand045OEEBasicallytherearetwodistinctivepointsofviewtolookattheOEE:Base:24hx365daysperyearInterest:ViewpointofCapacityManagementOEEManagementPerspectiveOEELinePersonnelPerspectiveBase:Plannedshiftcoverage(e.g.2shifts,5days)Interest:ImprovementActivitiesofthePersonnelthroughthelossestheycanactonKobetsuKaizen®Stand046OEEBreaksMaintenance/CleaningTrainingBreakdowns/RepairsProductionchangeoverToolchange/AdjustmentsStartup/ShutdownOverTaktTimeMicrostops10minEmptyRunsErrors/DefectsScrapReworkStopsPerformanceLossesQuality-LossesEffectiveUtilizationTypesofLossesunplannedplannedKobetsuKaizen®Stand047OEETotalTimeAvailableTimeProductiveTimeEffectiveTimeAvailabilityLossesPerformanceLossesQualityLosses-Scrap-Defects-ReworkTheOEEisdecreasedbyallevents,whicharenotvalueadding:OEECalculation-70min-80min-20minPlanned-Breaks,Maintenance,Cleaning-Changeover,Adjustment,ToolchangeUnplanned-Breakdowns,Repairs-OverTaktTime-Microstops(10min)-EmptyRuns(e.g.duetomissingmaterial/personnel)-StartupandShutdownlossese.g.480mine.g.400mine.g.330mine.g.310minKobetsuKaizen®Stand048OEEPerformanceRate=AvailableTime–PerformanceLossesAvailableTime=400min-70min400minQualityRate=ProductiveTime–QualityLossesProductiveTime=330min-20min330minAvailabilityRate=TotalTime-AvailabilityLossesTotalTime=480min–80min480minAR0,833PR0,825QR0,939XX=0,646=64,6%OEE(in%)=OEEcalculationapplyingAvailabilityRate,PerformanceRateandQualityRateAvailableTimeTotalTime==ProductiveTimeAvailableTime=EffectiveTimeProductiveTimeKobetsuKaizen®Stand049OEEOEE=EffectiveTimeTotalTimeOEE=NumberofpartsrightfirsttimeTotaltime/StandardCycleTimex100%x100%CalculationbasedontimeCalculationbasedonproducedpartsEffectiveUtilization∑LossesAlternativeCalculationModefortheOEELinePersonnelPerspectiveKobetsuKaizen®Stand0410Prioritizationofthelosses•UseaParetodiagramtovisuallyprioritizetheindividualtypesoflosses.•Toeachtypeoflossappropriatetoolsandmethodsareapplied.EffectiveUtilization∑LossesAdjustmentsBreakDownsMicroStopsChangeoversOEEPareto-/ABC-AnalysisChangeoversMicroStopsBreak-DownsAdjustmentsKobetsuKaizen®Stand0411DataGatheringGatheringappropriateandcorrectdataisaprerequisiteforimprovingtheOEE.GatheringallstopsandlossesonthemachineAnalyzingtheDataandDisplayingmeasurementsontheshopfloorHighlightpotentialimprovementsandstartwithimprovementactivitiesJFMAMJJASONDOEERepresentationTarget2005Analysis5101520253035RepairChangeOverToolChangeRejectsMicrostops33261673RepairsChangeover,Adjustmts.ToolchangeMicrostopsScrap,ReworkAutonomousMaintenancePreventiveMaintenanceProjectsforchangeovertimereductionImprovementoftoolutilizationdurationImprovementofequipmentcapabilitiesStandardizationKobetsuKaizen®Stand0412WordclasscompanieshaveanOEE85%HighavailabilityofmachinesandequipmentImprovedmachinecapabilitiesIncreasedAddedValue1.Decreaseofstocks1.Lessbreakdowns1.Highermachineefficiency2.Fasterflowtime2.StabileProcesses2.Costreduction3.Just-in-timedeliverytothecustomer3.ImprovedQuality3.ImprovedbusinessresultsQ1JITImpactoftheOEEoncompanies‘performanceKobetsuKaizen®Stand0413CustomerQualityProductivityEmployeesEnvironmentCustomerQualityOEE85%EmployeesEnvironmentJFMAMJJASONDIstSollJFMAMJJASONDIstSollJFMAMJJASONDIstSollJFMAMJJASONDIstSollJFMAMJJASONDIstSollJFMAMJJASONDIstSollJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstJFMAMJJASONDSollIstABC1.Problemrepresentation4.Solutionexamination2.Aproblemcause3.ProblemsolutionWhyWhyWhyWhyWhyTimexyzabczyxdefursObjectivesMetric/IndicatorsMeasures/ActionsCompanyobjectivesDepartment/AreaobjectivesAnalysisActionPlanCheckDoProblemsolvingMeasure/ActionsheetWho?What?DeadlineProblemsolvingstoryAreaobjectivesOEEOthersAvailability-factorPerformancefactorQualityfactorUnplannedstopsChangeoverStartupToolchangeCycletimeMicrostopsRew