Performance Rating of Production Facilities

Contents
Scope of rating Losses in production General time model DIN 8782 OEE OPI Example Perspective of filling line manufacturer

Scope of rating
Depending on the perspective of the person asking for a certain figure the scope of rating differs tremendously:

Scope of rating
Based on the perspective and the sector of industry many terms and figures are determined, e.g.: Efficiency Effectiveness Utilization factor Availability Performance efficiency Overall Equipment Effectiveness Overall Performance Indicator

Losses in production
Reasons for losses in production can be split up generally: Not scheduled time Unscheduled time Scheduled downtime Prod. changeover Breakdown
Weekend, public holiday, ... No order, No activity (NoNa) Training, maintenance, overhaul, cleaning, ... Clearing production, set up of machines, ... - Machine breakdowns (malfunction) - NON-machine breakdowns (maloperation of personnel, missing utilities, poor quality of material to be processed, ...) Reduced speed of master machine due to lack of product Faulty fill height / label position, damaged packaging, ...
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Reduced speed Rejects

General time model

Total time (Kalenderzeit) Manned time (geplante Personalzeit) Loading time (Arbeitszeit) Available production time (Betriebszeit) Operating time (Laufzeit) Production time Eff. Prod. time
Source: Dr.-Ing. T. Voigt

Not scheduled Unscheduled Scheduled downtime Product changeover

Breakdown Reduced speed

Rejects

DIN 8782 (Beverage industry)

Working time (Arbeitszeit)

Utilization factor of filling line

Operating time (Betriebszeit) General running time (Allgemeine Laufzeit) Effective running time
Rejects (master) - Breakdown (machine) - Red. speed Breakdown (NON- machine)

Scheduled downtime

Product changeover

Efficiency of filling line

Overall Equipment Effectiveness (OEE) Original OEE:

Extended OEE:

Overall Equipment Effectiveness (OEE)

Source: Dr.-Ing. T. Voigt

Extended Overall Equipment Effectiveness

Source: Dr.-Ing. T. Voigt

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Overall performance Indicator (OPI)

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Overall performance Indicator (OPI)

Source: Dr.-Ing. T. Voigt

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Comparison of indicators (Example)

Status Production Not scheduled time Unscheduled time Scheduled downtime Prod. changeover Breakdown Reduced speed Rejects

Min. 4480 2880 450 560 960 470 120 160

Gantt chart of 1 week

Source: Dr.-Ing. T. Voigt

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Comparison of indicators (Example)

* No distinction between machine and non-machine breakdowns

Source: Dr.-Ing. T. Voigt

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Conclusion
Qualification of index: DIN 8782:
Tender documents, acceptance test of filling line (line efficiency)

OEE:
Convenient index for ongoing technical controlling by owner/operator

OPI:
Comprehensive concept for benchmark of different production facilities applied by owner/operator

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Perspective of filling line manufacturer

Guarantee of filling line efficiency according to DIN 8782
This index allows a clear distinction of performance reducing impacts (responsibility of the manufacturer and owner/opperator is clearly defined for the beverage industry; e.g. splitting up of breakdown reasons)

Performance Optimization Service (POS)

This service detects and eliminates bottlenecks and weak spots at production facility by analysing intralogistics (storage facilities, material handling, loading processes, etc.) POS is performed by an task related team of experts using latest analysis and simulation tools

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Thank you very much for your attention!