Question

In: Operations Management

Below is data captured from last week’s production numbers on machining center AG-03: Scheduled operation =...

Below is data captured from last week’s production numbers on machining center AG-03:

Scheduled operation = 10 hours per shift, 1 shift, 5 days per week

Lunch = 30 minutes per day

Breaks = Two 15 minutes per day

Morning Huddle Meeting = 10 minutes per day

Planned 5S Activities = 5 minutes per day

Planned Maintenance = 25minutes per week

Standard cycle time = 0.5 minutes per unit

Below is the Operator Downtime Log Sheet for the Week on Machining Center AG-03

Day

Event

Time (min)

Monday

Setup

75

Material Shortage

20

Sensor Blocked

15

Tuesday

Maintenance Repair

120

Setup

90

Jam

10

Jam

15

Jam

10

Wednesday

Setup

60

Sensor Blocked

15

Thursday

Breakdown

240

Setup

70

Insert/ Wearable Tooling Replacement

15

Friday

Setup

115

Sensor Blocked

15

Below is the Operator Production Log Sheet for the Week on Machining Center AG-03

Day

Total Quantity Produced

Defects

Monday

738

45

Tuesday

495

28

Wednesday

791

18

Thursday

360

35

Friday

690

26

Total

3074

152

Calculate OEE for the week (5 days) using the data provided. Show all work.

What is your assessment of the current situation?

What specific steps would you take to improve OEE?

Solutions

Expert Solution

Monday
OEE DATA
Shift Length (Minutes) : 600 a
Number of Shift(s) : 1 b
Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c
Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d
Down Time (Minutes) : 115 e
Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f
Total Pieces Produced per Shift: 738 g
Rejected Pieces per Shift: 45 h
OEE VARIABLES CALCULATION
Planned Production Time (Minutes) : 525 i = (a-(c+d))*b
Operating Time (Minutes) : 410 j = i-(e*b)
Good Pieces per Shift: 693 k = g-h
OEE FACTORS CALCULATION
Availability 78.1% 90.0% l = j/i
Performance 90.0% 95.0% m = g/(f*j)
Quality 93.9% 99.9% n = k/g
Overall OEE 66.0% 85.4% o = l*m*n
Tuesday
OEE DATA
Shift Length (Minutes) : 600 a
Number of Shift(s) : 1 b
Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c
Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d
Down Time (Minutes) : 260 e
Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f
Total Pieces Produced per Shift: 495 g
Rejected Pieces per Shift: 28 h
OEE VARIABLES CALCULATION
Planned Production Time (Minutes) : 525 i = (a-(c+d))*b
Operating Time (Minutes) : 265 j = i-(e*b)
Good Pieces per Shift: 467 k = g-h
OEE FACTORS CALCULATION
Availability 50.5% 90.0% l = j/i
Performance 93.4% 95.0% m = g/(f*j)
Quality 94.3% 99.9% n = k/g
Overall OEE 44.5% 85.4% o = l*m*n
Wednesday
OEE DATA
Shift Length (Minutes) : 600 a
Number of Shift(s) : 1 b
Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c
Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d
Down Time (Minutes) : 80 e
Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f
Total Pieces Produced per Shift: 791 g
Rejected Pieces per Shift: 18 h
OEE VARIABLES CALCULATION
Planned Production Time (Minutes) : 525 i = (a-(c+d))*b
Operating Time (Minutes) : 445 j = i-(e*b)
Good Pieces per Shift: 773 k = g-h
OEE FACTORS CALCULATION
Availability 84.8% 90.0% l = j/i
Performance 88.9% 95.0% m = g/(f*j)
Quality 97.7% 99.9% n = k/g
Overall OEE 73.6% 85.4% o = l*m*n
Thursday
OEE DATA
Shift Length (Minutes) : 600 a
Number of Shift(s) : 1 b
Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c
Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d
Down Time (Minutes) : 330 e
Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f
Total Pieces Produced per Shift: 360 g
Rejected Pieces per Shift: 35 h
OEE VARIABLES CALCULATION
Planned Production Time (Minutes) : 525 i = (a-(c+d))*b
Operating Time (Minutes) : 195 j = i-(e*b)
Good Pieces per Shift: 325 k = g-h
OEE FACTORS CALCULATION
Availability 37.1% 90.0% l = j/i
Performance 92.3% 95.0% m = g/(f*j)
Quality 90.3% 99.9% n = k/g
Overall OEE 31.0% 85.4% o = l*m*n
Friday
OEE DATA
Shift Length (Minutes) : 600 a
Number of Shift(s) : 1 b
Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c
Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d
Down Time (Minutes) : 130 e
Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f
Total Pieces Produced per Shift: 690 g
Rejected Pieces per Shift: 26 h
OEE VARIABLES CALCULATION
Planned Production Time (Minutes) : 525 i = (a-(c+d))*b
Operating Time (Minutes) : 395 j = i-(e*b)
Good Pieces per Shift: 664 k = g-h
OEE FACTORS CALCULATION
Availability 75.2% 90.0% l = j/i
Performance 87.3% 95.0% m = g/(f*j)
Quality 96.2% 99.9% n = k/g
Overall OEE 63.2% 85.4% o = l*m*n
Asessment of the current situation is as follows:
The total defects were   5% of production It can be brought down to between 1 to 2 %
Daily downtime 183 minutes It can be reduced by reducing break down hours
Set up time per week 410 min per week 82 minutes per day should be reduced to 60 minutes
break down per week 240 minutes regular preventive maintenance is required
sensor blocked 45 minutes per week Safety training need to be addressed
repair maintenance 120 minutes Regular preventive maintenance is required
jam 35 minutes
insert wearable tooling replacement 15 minutes
Specific Steps to improve OEE are as follows:
1. Regular preventive maintenace
2. Reduce the number of defects
3. Reduce the setup time
4. Train the employees for safety systems

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