In: Operations Management
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?
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 |