Guide: Overall Equipment Effectiveness (OEE)

Implementing OEE in Manufacturing

Implementing and tracking Overall Equipment Effectiveness (OEE) requires a systematic approach to data collection and measurement. 

Understanding What to Measure

Before going into data collection, it’s important to understand the three core components of OEE:

1. Availability: Measures how often equipment is available versus the planned production time.
2. Performance: Assesses if the equipment is running at its optimal speed.
3. Quality: Looks at the proportion of good products versus the total produced.

Step 1: Setting Up for Data Collection

Identify Data Points

• For Availability: Track planned production time and downtime (including reasons for downtime like maintenance, breakdowns, or setup time).
• For Performance: Record the actual number of units produced and compare it with the theoretical output if the machine were running at optimal speed.
• For Quality: Count the number of good units and the total units produced, including those that are defective or require rework.

Choose Your Tools

• Manual Logging: For smaller operations, manual logging using forms or spreadsheets may suffice.
• Automated Systems: Larger or more technologically advanced facilities might opt for sensors and software that automatically track and log data such as PLC and SCADA.

Step 2: Data Collection Process

Implement a consistent routine for collecting data. Decide on a regular interval for data collection that suits the pace of the business; it could be shift-wise, daily, or hourly, depending on your operation’s scale. Ensure that the data is collected in the same way each time to maintain consistency. This will be important when analyzing data over time to understand changes in terms of up trends and downtrends, but also the impact of changes and improvements to processes and how this impacts OEE.

Train Your Team

Make sure all relevant staff are trained in how and what data to collect if it is a manual data collection process. Provide clear, written instructions and guidelines for data collection. If this is an automated process, ensure that the equipment will be able to collect the data reliably and consistently for the output results.

Step 3: Measuring and Calculating OEE

Availability

$\text{Availability}=\left(\frac{\text{Actual Operating Time}}{\text{Planned Production Time}}\right)\times 100\mathrm{\%}$

Performance

$\text{Performance}=\left(\frac{\text{Total Count of Units Produced}}{\text{Total Count Possible at Optimal Speed}}\right)\times 100\mathrm{\%}$

Quality

$\text{Quality}=\left(\frac{\text{Number of Good Units}}{\text{Total Units Produced}}\right)\times 100\mathrm{\%}$

Overall OEE

$\text{OEE}=\text{Availability}\times \text{Performance}\times \text{Quality}$

Step 4: Recording and Reviewing Data

Keep a record of all data collected in an organized manner. Regularly review the data to identify trends, patterns, or areas of concern. This will likely be part of the role of a production manager to review and report the KPI of OEE and any impacts on OEE in a given period of time.

Step 5: Continuous Improvement

Use the data to make informed decisions about improvements in processes or equipment. Remember, OEE tracking is an ongoing process. Regularly revisit and refine your data collection methods based on what you learn.

This simple guide serves as a starting point for implementing OEE in your manufacturing process. It’s important to adapt and modify this approach based on the specific needs and scale of your operation. Remember, the key to effective OEE implementation is consistency, accuracy, and a commitment to continuous improvement.