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Overall Equipment Effectiveness OEE Calculation Eight Major Plant - - PowerPoint PPT Presentation
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
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OEE Calculation
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Eight Major Plant Losses
- Sr. No.
Losses Definition Units Example 1 Shutdown loss Time lost when production or for planted annual shut down maintenance or periodic servicing Hours Shutdown work, periodic services, Statutory Inspection, autonomous inspection, general repair work etc 2 Production adjustment loss Time lost when changes in supply and demand require adjustment to production plans Hours Production- adjustment shutdown, inventory-reduction shutdown, etc 3 Equipment failure loss Time lost when equipment suddenly loses its specified functions Hours Failed pumps, burned-out motors, damaged bearing, broken shafts, etc 4 Process failure loss Time lost in shut down due to external factors such as changes in chemical or physical properties of materials being processed, operating errors, defective raw materials, etc Hours Leaks, spills, blocks, corrosion, erosion, dust scatter, misoperation
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Eight Major Plant Losses
- Sr. No.
Losses Definition Units Example 5 Normal production loss Rate and time losses at plant startup, shutdown, or changeover Rate decrease, hours Production rate reductions during warmup period after startup, cooldown period before shutdown, and product changeover 6 Abnormal production loss Rate loss occurring when plant underperforms due to malfunctions and abnormalities Rate decrease Low-load operation, low-speed
- peration, and operation at below
standard production rate 7 Quality defect loss Losses due to producing rejectable product, physical loss
- f rejected product, financial
losses due to product downgrading Hours, tons, rupees Physical and time losses due to making product that fails to meet quality standards 8 Reprocessing loss Recycling losses due to passing material back through the process Hours, tons, rupees Recycling nonconforming product from the final process to the starting process to make it acceptable
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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)
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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
No.Date Time Start Time Finish Down (min) Replaceme 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 10 25-Feb 3:30 PM 4:30 PM 60Parts 09 11 26-Feb 10:30 AM 12:00 PM 90Parts 12 12
Total down time (min)
1,920
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Date Shutdown loss Production adjustment loss Equipment failure loss Process failure loss Normal production loss Abnormal production loss Quality defect loss Reprocessi ng loss
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