Machine: MITSUBISHI 5 COLOR PRINTING PRESS

Product: Reynolds Jetter

Expected Production per hour: 12000
Machine's Catalog Capacity per hour: 16000

Target: 100.00% AVAILABLE TIME = 24 HOURS

THEORETICAL EXPECTED PRODUCTION = 24 * 12000 = 288000

Stage 1: 91.67% PLANNED TIME = 22 HOURS

ESTIMATED PRODUCTION = 22 * 12000 = 264000

Stage 2: 83.33% AVAILABLE TIME = 20 HOURS

ACHIEVABLE PRODUCTION = 20 * 12000 = 240000

Stage 3: 79.17% MINOR STOPPGES, SPEED LOSSES CONTRIBUTING 1 HOUR = 19 HOURS

FIRST STAGE POSSIBLE PRODUCTION = 19 * 12000 = 228000

Stage 4: 75.00% YIELD LOSS DUE TO SPEED UP / DOWN CONTRIBUTING 1 HOUR = 18 HOURS
SECOND STAGE POSSIBLE PRODUCTION = 18 * 12000 = 216000

Stage 5: 70.83% QUALITY LOSS / REWORK LOSSES CONTRIBUTING 1 HOUR = 17 HOURS

THIRD STAGE POSSIBLE PRODUCTION = 17 * 12000 = 204000

Machine Availibility: 90.91% (Number of Actual Hours machine has run / Number of Act

Speed Rate: 77.27% (Actual Final Speed / Desired Speed for the product)

Quality Rate: 94.12% (Quantity finally accepted / Quantity finally produced)

OEE: 66.11% Multiply all above to obtain Overall equipm

 Per day time
available for production

2 hours for meeting, cleaning

preventive maintenance etc.

Machine stopped during production due to

set up, adjustments, breakdown etc. > 10 mins.

1 HOUR = 19 HOURS Machine slowing down, speeding up

jams, sensor faults etc. < 10 mins.

NG 1 HOUR = 18 HOURS Whenver the machine stops and starts it

needs time to rise to set speed / to slow down

HOUR = 17 HOURS
204000

ine has run / Number of Actual Hours machine can run)

Speed for the product)

antity finally produced)

btain Overall equipment efficiency

for production

ction due to
n etc. > 10 mins.
 Machine: Battenfeld TC40 Controlled Molding m/c
Product: 907 Fuse Housing, Single Cavity
Material: PA6,6 20% GF
Calculated Cycle Time: 45 seconds (20 seconds cooling time)
Calculated Output per hour: 80 Morning Meetings, Machine
Ideal Working Hours per day: 24 Morning Meetings, Machine
Cleaning, Material Pre-heating,
Cleaning, Material Pre-heating,
Mold Servicing, Production
Mold Servicing, Production
Number of Hours Planned Preparation and other planned
A 22 Preparation and other planned
Per day: stoppages
stoppages

B Downtimes 3
When m/c running, it stops due to
When m/c running,
breakdowns, it stopsrunner
power failures, due to
breakdowns,
catching, lump power failures,
formation, waterrunner
Nett machine running catching,
leakages lump
and formation,
more. water
The machine
C (available time) = A - B 19 leakages
totally and more. The machine
STOPS.
totally STOPS.

Theoretical expected
D production @ 80
components per hour
Actual Quantity Produced
E 1140
for run hours
1520
Due to various limitations on the
Due to various limitations on the
machines, mold, material, skill the
machines, mold, material, skill the
theoretical cycle time is never
theoretical cycle time is never
achieved. In this example we have
achieved. In this example we have
reduced output to 60 per hour
reduced output to 60 per hour

Quantity rejected due to

F various reasons
Nett output achieved at the
G 940
end of the day
200
Due to in-process as well as after
Due to in-process as well as after
production problems, 100
production problems, 100
numbers are rejected. Please
= E-F numbers are rejected. Please
include customer end or upstream
include customer end or upstream
process rejection also.
process rejection also.

H Machine Availibility C/A

86.4%

I Yield Loss E/D

75.0%

J Quality Loss G/E

 82.5%

Overall Equipment H*I*J

Effectiveness ( O E E ) 53.4%

6 MAJOR LOSSES AS ADVOCATED BY T P M

BREAKDOWN
LOSSES
IDLING &
MINOR
STOPPAGES
SET UP &
ADJUSTMENT
LOSSES

SPEED
LOSSES

YIELD QUALITY
LOSSES REWORK &
DEFECTS