Methode untuk memonitoring downtime dalam suatu proses produksi

1. OEE
(Overall Equipment Effectiveness)
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2. What is OEE?
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Definition
Objectives / Goals
Methodologies
Who should involve?
OEE Calculation
Six Bis Losses
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3. OEE Definition
• OEE (Overall Equipment Effectiveness) Is an
abbreviation for the manufacturing metric
Overall Equipment Effectiveness. OEE takes
into account the various sub components of
the manufacturing process – Availability,
Performance and Quality.
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4. • OEE is a "best practices" way to monitor and
improve the effectiveness of your
manufacturing processes (i.e. machines,
manufacturing cells, assembly lines).
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5. OEE Objectives / Goals
• Zero Losses
– Zero Breakdowns
– Zero Defects
– Zero Accidents
• Sustainable Continuous Improvement
– Team based activities
– Not depend on certain people
• World Class Manufacturing company
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6. OEE Methodologies
• Team based  Teamwork
• Data & Fact based
– Measuring
– Controlling
• Prioritization
• Continuous Learning & Improvement
• Commitments
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7. Who will do OEE?
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Production
Engineering / Maintenance
Quality Control / Assurance
Human Resources Development
Management
And all related parties who can contribute
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8. OEE Calculation
OEE =
Availability
X
Performance
X
Quality
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9. Availability
• Is the machine operating or not?
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10. • Example:
Machine operating 1080 minute in 1 Day (24
Hour = 1440 minute)
=1080/1440 x 100
=75 %
• Availability Time = 75 %
• Availability Losses = 25 %
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11. Performance
• How fast is the machine running?
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12. • Example:
Machine operate/Design = 500 Kg/Hour
Operting time = 1080
= (1080/60) x 500 = 9000 Kg = 9 Ton
Actual Output = 8640 Kg
• Performance
= (8640 / 9000) x 100
= 96 %
• Performance Losses = 4 %
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13. Quality
• How many products good?
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14. • Example:
Actual Product
Rejected
Good Product
= 8640 Kg
= 60 Kg
= 8640 – 60 = 8580 Kg
• Quality
= (8580 / 8640) x 100
= 99,3 %
• Quality Losses = 0,7 %
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15. OEE COMPOSITION
Total time
Yearly
Maint.
Labour. Team maint.
ratio.
Plan.Eff.
- Shift system
Effective working time
NONA
- Nights & Weekends
unmanned
Preparation
- Holidays
Change
over
time
Available production time
- Idle time
-Set-up and
equipment adjustment
- “Extra” cleaning,
training, meetings
- Cleaning
no electricity, no steam, - Trial
no compressed air, no
- Start-up / Shut down
water
mesin
-Breakdowns mechanical (>
15 minutes)
Speed
losses &
minor stops
- Speeds less than nominal capacity
- Minor stops (< 15 minutes)
Theoretical Prod. Time =
- All quality defects
good product / nom.capacity
including products on hold
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OPI
OPI NONA
Reject &
rework
-No Order No Activity
Quality
Good product or
Theoretical
Production time
- shut down / overhole
Performance
Break
down
time
Operating time
Production time
Planned
downtime
External
stops
Actual production time
Efficiency
Unused
time
Availability
Effectivity
Manned time

16. SIX BIG LOSSES
1.
2.
3.
4.
5.
6.
Unused Time
Planned Downtime & Change Over
External Causes
Break Downtime
Performance Losses
Quality Losses
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17. OEE Template
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18. Created by Anang