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OEE tells us how well the machine is performing, not how well

we are utilising the machine.

OEE asks the question whether a machine is doing what it issupposed to be doing. Put differently, it answers the

following questions about the period that the machine isscheduled to produce:

For how much of that time is it actually operating?

At what rate is it operating in comparison to its design rate?

Is it producing good quality product from start to finish?

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OEE is a diagnostic tool for improvement. It diagnoses the machine (like a doctor)and tells us what is wrong and where we can improve. If measured over a periodof time, it also will tell us whether we are being successful in our efforts toimprove.

There are six machine losses (like diseases or deficiencies). They are: Breakdowns

Changeovers, start-ups, set-ups, adjustments

Short stops and idling time

Speed loss / reduction

Poor start-up quality

Poor production quality (defects and rework).

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OEE as a diagnostic tool

OEE not only answers how well the machine is running, but also why it is not running 100%. Is it due to speed loss? Or changeovers? Or

long machine start-ups? OEE thus tells us where to start with the improvement effort.

When looking at our machines, we can determine where the greatest weak point is by looking at the results of the OEE measurement

over a period of time. The best is always to look at a period greater than one week to ensure that a certain product or incidence does

not distract us from the real issue. We determine this by asking the 5 Whys as follows:

1. WHY is the OEE so low?

Looking at the OEE calculation, it might indicate that availability is the lowest of the three categories.

2. WHY is availability so low?

The reason might be that there were no breakdowns, but there were a number of short stops.

3. WHY were there so many stops?

The reason might be, for example, that some time was wasted due to waiting for latecomers, but most time wasted wasspent on changeover.

4. WHY did the changeover take so long?

The right change parts could not be found.

5. WHY could the change parts not be found?

The line is disorganised and there is no specific place where the change parts are kept.

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Availability - Increase machine/line availability Collect data

Measure machine/line availability

Analyse data

Identify actions to improve availability.

Performance - Increase machine/line speed Collect data

Measure machine/line performance

Analyse data

Identify actions to improve performance, de-bottleneck production lines.

Quality - Improve product quality Collect data

Measure machine/line quality

Analyse data

Identify actions to improve quality.

Operator efficiency - Increase operation rate of operators Collect data (with man-machine charts and activity sampling)

Measure operator work rate (as described in activity sampling)

Analyse data

Identify opportunities for multi-machine/line operation (supported by Key 15 Skill Versatility and Cross Training)

Identify actions to eliminate monitoring and other non-value adding operators' motions.

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