Overall Equipment Effectiveness OEE Calculation Eight Major Plant - PowerPoint PPT Presentation

Overall Equipment Effectiveness

OEE Calculation

Eight Major Plant Losses Sr. No. Losses Definition Units Example 1 Shutdown loss Time lost when production or for planted Hours Shutdown work, periodic services, annual shut down maintenance or Statutory Inspection, autonomous periodic servicing inspection, general repair work etc 2 Production adjustment loss Time lost when changes in supply and Hours Production- adjustment shutdown, demand require adjustment to production inventory-reduction shutdown, etc plans 3 Equipment failure loss Time lost when equipment suddenly loses Hours Failed pumps, burned-out motors, its specified functions damaged bearing, broken shafts, etc 4 Process failure loss Time lost in shut down due to external Hours Leaks, spills, blocks, corrosion, erosion, factors such as changes in chemical or dust scatter, misoperation physical properties of materials being processed, operating errors, defective raw materials, etc

Eight Major Plant Losses Sr. No. Losses Definition Units Example 5 Normal production loss Rate and time losses at plant Rate decrease, hours Production rate reductions during startup, shutdown, or changeover warmup period after startup, cooldown period before shutdown, and product changeover 6 Abnormal production loss Rate loss occurring when plant Rate decrease Low-load operation, low-speed underperforms due to operation, and operation at below malfunctions and abnormalities standard production rate 7 Quality defect loss Losses due to producing Hours, tons, rupees Physical and time losses due to making rejectable product, physical loss product that fails to meet quality of rejected product, financial standards losses due to product downgrading 8 Reprocessing loss Recycling losses due to passing Hours, tons, rupees Recycling nonconforming product from material back through the the final process to the starting process process to make it acceptable

MTTR and MTBF • Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) are two important KPI's in plant maintenance. • MTBF = (Total up time) / (number of breakdowns) • MTTR = (Total down time) / (number of breakdowns)

MTBF and MTTR Calculator Month May 2019 Name of Machine M_3 Operation availability (min/mo) 24,960 Frequence 11 MTBF (min) 2,095 MTTR (min) 175 Time Replaceme No.Date Time Start Finish Down (min) nt Notes 1 01-Feb 10:00 AM 12:00 PM 120Parts 56 2 03-Feb 10:00 AM 12:00 PM 120Parts 98 3 04-Feb 10:00 AM 12:00 PM 120Parts 33 4 05-Feb 10:00 AM 12:00 PM 120Parts 11 5 06-Feb 10:00 AM 12:00 PM 120Parts 12 6 07-Feb 10:00 AM 12:00 PM 120Parts 98 7 15-Feb 6:00 AM 6:00 PM 720Parts 09 8 22-Feb 2:00 PM 6:00 PM 240Parts 12 9 25-Feb 10:30 AM 12:00 PM 90Parts 98 60Parts 09 10 25-Feb 3:30 PM 4:30 PM 11 26-Feb 10:30 AM 12:00 PM 90Parts 12 12 Total down time (min) 1,920

Production Normal Abnormal Quality Shutdown adjustment Equipment Process production production defect Reprocessi Date loss loss failure loss failure loss loss loss loss ng loss

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