What is OEE ?

OEE
Definition

Making OEE
part of Visual
Management

OEE
Overall Equipment
Effectiveness

How can i
influence
the OEE ?

KANZEN
INSTITUTE

OEE
Calculation

Why is a high OEE

important for the
department ?

Overall Equipment Effectiveness

OEE is the way to measure how effectively machine / equipment hours are used
(Value Adding)
Total time
e.g. 480 min. (1 shift)
Available time
Running time

Productive time

Effective time

KANZEN
INSTITUTE

OEE is loss due to:

Depending on definition TPM knows 6-16
different losses

Planned
Downtime

- breaks, planned
maintenance, training

Downtime

- breakdowns, repairs
- changeover
- adjustment
- start up

Performance
Losses

- machine speed
- short stoppages
- lower yield

Quality Losses

- scrap
- reject
- rework

Calculation of LOSSES
Total time
e.g. 480 min. (1 shift)
Planned
Downtime

- breaks, planned
maintenance, training

Running time
340 min.

Downtime

- breakdowns, repairs
- changeover
- adjustment
- start up

Productive time
270 min.

Performance
Losses

- long cycle time

- minor stoppages
- reduced yield

Quality Losses

- scrap
- rework
- rejects

Available time
420 min.

Effective time
250 min.
Total losses = 170 min / shift
KANZEN
INSTITUTE

Calculation of OEE
Running Efficiency =

Productive Performance=

Quality =

Available time - Downtime

Availability
420 min - 80 min

factor 81%

420 min

Running time - Performance loss

Running time
340 min 70 min
340 min

X
factor 79.4%

Productive time - Quality loss time

Productive time
270 min - 20 min
270 min

X
factor 92.6%

Overall Equipment Effectiveness

KANZEN
INSTITUTE

OEE (in %) =

= 59.6%

How to increase OEE ?

Data collection is the very important basis to increase OEE
Collect data for all downtime
and losses on the machine
Repairs
Change over, Adjustm.
Tool change

Data analysis and

visible measure
Analysis

35
30
25
20
15
10
5

Scrap, rework

Autonomous Mainten.
Preventive Maintenance
Changeover reduction

Repair

Minor stoppages

Make improvements
visible and implement

33

ChangeoverTool change

26

16

Scrap

Minor Stopp.

OEE Trend
Target 2003

Standardize tooling
Improved machine
reliability
Standardisation
Kaizen

J F M A M J J A S O N D

KANZEN
INSTITUTE

Making OEE visible

Machine Information
OEE trend machine 01
Target 2003

Departement Information

Company Information

OEE trend Machine 01

Target 2003

Data
J FMAMJ JASOND

J F M A M J J A S O N D

J F MA M J J A SOND

OEE trend Machine 02

OEE
Produktivity

Target 2003

J FMAMJ JASOND

J FMAMJ JASOND

J FMAMJ JASOND

Analysis

35
30
25
20
15
10
5

J F M A M J J A S O N D

other

J FMAMJ JASOND

OEE trend Machine 03

Target 2003
J FMAMJ JASOND
Repairs ChgeoverTool chg.

33

26

16

Scrap Min.Stop.

shows the current situation

of the machine or plant

KANZEN
INSTITUTE

J F M A M J J A S O N D

shows the machine

in the area

shows developement, trends

and links beween targets and
achievements

Structured matrix sheet

Effects of OEE improvement activities

company

OEE
in %

Date
.

Department

target

effect of improvement project

2003

2004

Measures
introduction training
removal of defects
elimination of defects
standards / check lists
improvement projects

KANZEN
INSTITUTE

Fundamental concept of plant effectiveness

16 Kinds of loss

8 availability losses

5 productivity losses

3 production/ cost losses

not part of OEE -

Machine failure

Management losses

Set up & adjustments

Motion

Loss of energy

Tool changes

Line organization

Die, Jig and tool losses

Start-up losses

Logistics

Minor stoppages

Adjustments

Speed Losses
Defects and Rework
Shutdown

KANZEN
INSTITUTE

Yield losses