Performance Ratingof Production Facilities

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Contents

� Scope of rating

� Losses in production

� General time model

� DIN 8782

� OEE

� OPI

� Example

� Perspective of filling line manufacturer

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Scope of rating

� Depending on the perspective of the person asking for a certain figure the

scope of rating differs tremendously:

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Scope of rating

� Based on the perspective and the sector of industry many terms and figures

are determined, e.g.:

� Efficiency

� Effectiveness

� Utilization factor

� Availability

� Performance efficiency

� Overall Equipment Effectiveness

� Overall Performance Indicator

� …

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Losses in production

Reasons for losses in production can be split up generally:

Not scheduled time

Unscheduled time

Scheduled downtime

Prod. changeover

Breakdown

Reduced speed

Rejects

Weekend, public holiday, ...

No order, No activity (NoNa)

Training, maintenance, overhaul, cleaning, ...

Clearing production, set up of machines, ...

- Machine breakdowns (malfunction)

- NON-machine breakdowns (maloperation of personnel,missing utilities, poor quality of material to be processed, ...)

Reduced speed of master machine due to lack of product

Faulty fill height / label position, damaged packaging, ...

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General time model

Unscheduled

Scheduled downtime

Product changeover

Breakdown

Reduced speed

Rejects

Total time (Kalenderzeit)

Manned time (geplante Personalzeit)Not

scheduled

Loading time (Arbeitszeit)

Available production time (Betriebszeit)

Operating time (Laufzeit)

Production time

Eff. Prod. time

Source: Dr.-Ing. T. Voigt

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DIN 8782 (Beverage industry)

Scheduled downtime

Product changeover

Breakdown(NON- machine)

Working time(Arbeitszeit)

Operating time(Betriebszeit)

General running time(Allgemeine Laufzeit)

Effective running time

- Breakdown(machine)

- Red. speed

Utilization factor of filling line

Efficiency of filling line

Rejects(master)

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Overall Equipment Effectiveness (OEE)

Original OEE:

Extended OEE:

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Overall Equipment Effectiveness (OEE)

Source: Dr.-Ing. T. Voigt

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Extended Overall Equipment Effectiveness

Source: Dr.-Ing. T. Voigt

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Overall performance Indicator (OPI)

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Overall performance Indicator (OPI)

Source: Dr.-Ing. T. Voigt

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Comparison of indicators (Example)

Gantt chart of 1 week

Not scheduled time

Unscheduled time

Scheduled downtime

Prod. changeover

Breakdown

Reduced speed

Rejects

2880

450

560

960

120

160

470

Production 4480

Status Min.

Source: Dr.-Ing. T. Voigt

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Comparison of indicators (Example)

* No distinction between machineand non-machine breakdowns

Source: Dr.-Ing. T. Voigt

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Conclusion

Qualification of index:

� DIN 8782:

� Tender documents, acceptance test of filling line (line efficiency)

� OEE:

� Convenient index for ongoing technical controlling by owner/operator

� OPI:

� Comprehensive concept for benchmark of different production facilities

applied by owner/operator

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Perspective of filling line manufacturer

� Guarantee of filling line efficiency according to DIN 8782

� This index allows a clear distinction of performance reducing impacts

(responsibility of the manufacturer and owner/opperator is clearly

defined for the beverage industry; e.g. splitting up of breakdown

reasons)

� Performance Optimization Service (POS)

� This service detects and eliminates bottlenecks and weak spots at

production facility by analysing intralogistics (storage facilities, material

handling, loading processes, etc.)

� POS is performed by an task related team of experts using latest

analysis and simulation tools

Thank you very muchfor your attention!