LOSSES OEE Workshop Siyambulela Bozo: Junior Project Manager AIDC - - PowerPoint PPT Presentation

OEE Workshop

Siyambulela Bozo: Junior Project Manager AIDC - TPM

OEE VS 6 BIG LOSSES

Pres resentation entation Ov Overview erview

• 1. What are Losses
• 2. Defining the 6 Big Losses
• 3. Measuring 6 Big Losses
• 4. How to Eliminate the 6 Big

Losses?

• Conclusion

1.

• 1. Wh

What at A Are re Lo Losses sses?

“ Losses in the production environment are those areas where the greatest amounts of materials and time is wasted” - Kunio Shirose, 1989

There are 16 Major Losses that can impede Improvement of Production Efficiency

A) 7 Ma Major

• r Losses that can impede equipment efficiency

B) 1 Ma Major

• r Loss that can impede machine loading time

C) 5 Major

• r Losses that can impede improvement of work

D) 3 Major

• r Losses that can impede effective use of production resources

2. 2.Defining Defining 6 B 6 Big g Lo Losses sses

2.

• 2. De

Defining fining 6 B 6 Big g Lo Losses sses

1.

• 1. Failure/Brea

re/Breakdown kdown Losses es

• Losses due to sporadic / chronic failures result in time

losses (declining output) and volume losses (defects)

• Losses requiring replacement or repair of machine

parts for machine to function

• Losses requiring 5-10 minute or more for repairs

Sporadic Failures

• Attract major attention and countermeasures are

immediately developed and implemented e.g. Tool Breakdown Chronic Failures

• Frequent failures which remain unresolved due to

ineffective countermeasures

2.

• 2. De

Defining fining 6 B 6 Big g Lo Losses sses

• 2. Set-up

up and Adjustment tment losses es

• Time losses from end of the production of a previous item,

through changeover and setup of new product tools

• Time losses after set-up by doing trial and error adjustments

to buy-off good part after many parts try out

• 3. Cu

Cuttin ting g Blade Losses

• Losses due to regular blade exchanges and other

blade replacement by blade damages and volume losses

• Losses due to breakage and chipping of blade, blade tip

rework

• Losses due to material and yield losses

2.

• 2. De

Defining fining 6 B 6 Big g Lo Losses sses

• 4. Start

rt-up p Losse ses

• Time losses from start-up after

periodic repair

• Time losses from start-up after

suspension (long-time stoppage)

• Time losses after lunch breaks
• 5. Min

inor r St Stoppage page / Idli ling g Losses s

• Losses due to temporary malfunction of machine
• Losses requiring removal of abnormal work pieces and

resetting

2.

• 2. De

Defining fining 6 B 6 Big g Lo Losses sses

• 6. Speed

ed losses sses

• Losses occurring due to

slow equipment speed

• Losses due to difference

between the design speed and the actual machine speed

• Losses caused when the

design speed is slower than present technological standards or the desirable condition

E.g. If standard cycle time is set at 60seconds, and actual operation time is 65seconds, speed loss is 5 seconds

3.

• 3. Measuri

easuring ng 6 Bi 6 Big g Lo Losses sses

OE OEE in Ch n China ina

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

4.

• 4. Eliminating

iminating 6 B 6 Big g Lo Losses sses

Co Conc nclusio lusion

Down Time

1. 1.

Break akdow downs ns due to equipment failure

• Apply Ishikawa Root Cause Analysis as a Team and solve root cause of equipment

2. Setup up and adjus ustment tment (e.g. exchange of dies in injection molding machines)

• Perform SMED Exercise

Speed d Losses es

3. 3.

Idling ng and minor

• r stoppage

ppages (abnormal operation of sensor, etc.)

• Cycle time analysis to see the process that frequently causes the stoppage

4. 4.

Reduc uced ed speed eed (discrepancies between designed and actual speed of equipment)

• Compare all cycle times to ideal cycle time and focus on eliminating errant times

Defect cts

5. 5.

Defects ts in proces ess and rework (scrap and quality defects requiring repair)

• Six Sigma (DMAIC Process Improvement Approach)

6. Reduced uced yield d between en machine hine startup tup and d stable ble producti duction

• n
• Six Sigma (DMAIC Process Improvement Approach)