In a 480 minute shift :-

On a machine rated at 100 products output per minute

Maximum output = 480 mins x 100 units = 48000 units

Shift info: Output (Good Production) = 32000 units

Speed = 98 units per minute

Planned downtime = 82 mins

Bottleneck loss due to B/down = 30 mins

Rejects (in process) = 1255 in 8 hr shift

Output (OEE) = 32000 / 48000 = 66.7%

480mins x 66.67% = 320 mins, therefore Total Loss = 160 mins

Six Loss Calculations:

Speed loss

Max theoretical units possible at actual speed = 98 x 480 = 47040

= (32000/47040) – (32000/48000) =

68.03% - 66.67% = 1.36%

480 x 1.36% = 6.53 mins / 480 = (1.36%)

Planned downtime = 82 mins / 480 = (17.08%)

Breakdown = 30 mins / 480 = (6.25%)

Rejects = 1255 / 98 (actual running speed) = 12.81 mins / 480 = (2.67%)

Minor stops = 480-320-6.53-82-30-12.81 = 28.66 mins / 480 = (5.97%)

Total loss = 160 mins = (33.33%)

OEE Calculations (Time in mins):

Production time = 480 Time less availability loss = 368Time less performance loss = 333

Availability Loss Performance Loss Quality Loss

Planned downtime =82 Speed loss =6.53Rejects on start up =0

Breakdowns =30Minor stops (<5mins) =28.66 Rejects in process =12.81

Total =112Total =35.19 Total =12.81

Availability (368/480) = 77% Performance (333/368) = 90% Quality (320/333) = 96%

OEE = 0.77x0.9x0.96 = 66.7%

 

Transform these information into our OEE Table and prove the "availability", "efficiency(?)", "performance", "Reliability-Throughput Yield", "OEE" measures with open calculation. To prepare an Excell sheet is NOT done. Show your calculations,.... What are the major differences, between both approaches (our and the Case above)? Mention at least three of them. As a consultant where would start? Why explain?