Below is data captured from last week’s production numbers on machining center A
ID: 331737 • Letter: B
Question
Below is data captured from last week’s production numbers on machining center AG-03:
Scheduled operation = 10 hours per shift, 1 shift, 5 days per week
Lunch = 30 minutes per day
Breaks = Two 15 minutes per day
Morning Huddle Meeting = 10 minutes per day
Planned 5S Activities = 5 minutes per day
Planned Maintenance = 25minutes per week
Standard cycle time = 0.5 minutes per unit
Below is the Operator Downtime Log Sheet for the Week on Machining Center AG-03
Day
Event
Time (min)
Monday
Setup
75
Material Shortage
20
Sensor Blocked
15
Tuesday
Maintenance Repair
120
Setup
90
Jam
10
Jam
15
Jam
10
Wednesday
Setup
60
Sensor Blocked
15
Thursday
Breakdown
240
Setup
70
Insert/ Wearable Tooling Replacement
15
Friday
Setup
115
Sensor Blocked
15
Below is the Operator Production Log Sheet for the Week on Machining Center AG-03
Day
Total Quantity Produced
Defects
Monday
738
45
Tuesday
495
28
Wednesday
791
18
Thursday
360
35
Friday
690
26
Total
3074
152
Calculate OEE for the week (5 days) using the data provided. Show all work.
What is your assessment of the current situation?
What specific steps would you take to improve OEE?
Day
Event
Time (min)
Monday
Setup
75
Material Shortage
20
Sensor Blocked
15
Tuesday
Maintenance Repair
120
Setup
90
Jam
10
Jam
15
Jam
10
Wednesday
Setup
60
Sensor Blocked
15
Thursday
Breakdown
240
Setup
70
Insert/ Wearable Tooling Replacement
15
Friday
Setup
115
Sensor Blocked
15
Explanation / Answer
Monday OEE DATA Shift Length (Minutes) : 600 a Number of Shift(s) : 1 b Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d Down Time (Minutes) : 115 e Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f Total Pieces Produced per Shift: 738 g Rejected Pieces per Shift: 45 h OEE VARIABLES CALCULATION Planned Production Time (Minutes) : 525 i = (a-(c+d))*b Operating Time (Minutes) : 410 j = i-(e*b) Good Pieces per Shift: 693 k = g-h OEE FACTORS CALCULATION Availability 78.1% 90.0% l = j/i Performance 90.0% 95.0% m = g/(f*j) Quality 93.9% 99.9% n = k/g Overall OEE 66.0% 85.4% o = l*m*n Tuesday OEE DATA Shift Length (Minutes) : 600 a Number of Shift(s) : 1 b Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d Down Time (Minutes) : 260 e Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f Total Pieces Produced per Shift: 495 g Rejected Pieces per Shift: 28 h OEE VARIABLES CALCULATION Planned Production Time (Minutes) : 525 i = (a-(c+d))*b Operating Time (Minutes) : 265 j = i-(e*b) Good Pieces per Shift: 467 k = g-h OEE FACTORS CALCULATION Availability 50.5% 90.0% l = j/i Performance 93.4% 95.0% m = g/(f*j) Quality 94.3% 99.9% n = k/g Overall OEE 44.5% 85.4% o = l*m*n Wednesday OEE DATA Shift Length (Minutes) : 600 a Number of Shift(s) : 1 b Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d Down Time (Minutes) : 80 e Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f Total Pieces Produced per Shift: 791 g Rejected Pieces per Shift: 18 h OEE VARIABLES CALCULATION Planned Production Time (Minutes) : 525 i = (a-(c+d))*b Operating Time (Minutes) : 445 j = i-(e*b) Good Pieces per Shift: 773 k = g-h OEE FACTORS CALCULATION Availability 84.8% 90.0% l = j/i Performance 88.9% 95.0% m = g/(f*j) Quality 97.7% 99.9% n = k/g Overall OEE 73.6% 85.4% o = l*m*n Thursday OEE DATA Shift Length (Minutes) : 600 a Number of Shift(s) : 1 b Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d Down Time (Minutes) : 330 e Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f Total Pieces Produced per Shift: 360 g Rejected Pieces per Shift: 35 h OEE VARIABLES CALCULATION Planned Production Time (Minutes) : 525 i = (a-(c+d))*b Operating Time (Minutes) : 195 j = i-(e*b) Good Pieces per Shift: 325 k = g-h OEE FACTORS CALCULATION Availability 37.1% 90.0% l = j/i Performance 92.3% 95.0% m = g/(f*j) Quality 90.3% 99.9% n = k/g Overall OEE 31.0% 85.4% o = l*m*n Friday OEE DATA Shift Length (Minutes) : 600 a Number of Shift(s) : 1 b Short Breaks per Shift (Minutes) : Each (Minutes) : 15 Nb : 2 Total : 30 c Meal Break per Shift (Minutes) : Each (Minutes) : 45 Nb : 1 Total : 45 d Down Time (Minutes) : 130 e Ideal Rate : (Pieces/Hour) : 120 (Pieces/Minute) : 2 f Total Pieces Produced per Shift: 690 g Rejected Pieces per Shift: 26 h OEE VARIABLES CALCULATION Planned Production Time (Minutes) : 525 i = (a-(c+d))*b Operating Time (Minutes) : 395 j = i-(e*b) Good Pieces per Shift: 664 k = g-h OEE FACTORS CALCULATION Availability 75.2% 90.0% l = j/i Performance 87.3% 95.0% m = g/(f*j) Quality 96.2% 99.9% n = k/g Overall OEE 63.2% 85.4% o = l*m*n Asessment of the current situation is as follows: The total defects were 5% of production It can be brought down to between 1 to 2 % Daily downtime 183 minutes It can be reduced by reducing break down hours Set up time per week 410 min per week 82 minutes per day should be reduced to 60 minutes break down per week 240 minutes regular preventive maintenance is required sensor blocked 45 minutes per week Safety training need to be addressed repair maintenance 120 minutes Regular preventive maintenance is required jam 35 minutes insert wearable tooling replacement 15 minutes Specific Steps to improve OEE are as follows: 1. Regular preventive maintenace 2. Reduce the number of defects 3. Reduce the setup time 4. Train the employees for safety systems
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