1. OVERALL EQUIPMENT EFFECTIVENESS (O E E)
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TPM
OVERALL EQUIPMENT EFFECTIVENESS (O E E)
A practical approach to problem solving & increasing 
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

2. HOW IS YOUR MACHINE’S  MEASURED ?
TPM
HOW IS YOUR MACHINE’S  MEASURED ?
PROCESSED OUTPUT / PLANNED OUTPUT ?
ACHIEVED HOURS / PLANNED HOURS ?
ACTUAL DELIVERY / PLANNED DELIVERY ?
QUANTITY ACCEPTED / (QUANTITY ACCEPTED + QUANTITY REJECTED ) ?
Any other method...
Over last 3 months, was your machine  more than 85% ?
Over last 3 months, was your machine downtime less than 3% ?
Are your customers happy with your product & delivery ?
If your answer is YES or NO to above questions, it’s time to measure O E E
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

3. TPM
What is O E E ?
Overall Equipment Effectiveness is a measure of equipment’s NETT
efficiency taking into account, following six major losses, advocated
in TPM
BREAKDOWN LOSSES
SET UP & ADJUSTMENT LOSSES
IDLING & MINOR STOPPAGES
SPEED LOSSES
REDUCED YIELD
QUALITY REWORK / REJECTS
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

4. TPM BREAKDOWN LOSSES Sporadic stoppage of machine
Un-noticed failure of certain components
Accelerated deterioration of equipment
Repetition of certain problems, during production
Major downtimes affecting production
Function loss & Function reduction
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

5. TPM SET UP & ADJUSTMENT LOSSES
Repeated adjustments of process parameters during production
Non-standard approach to tool / process setting
Frequent order changes on a machine
Repetition of certain problems, during production
Major downtimes affecting production
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

6. TPM IDLING & MINOR STOPPAGES
Repeated jams / sensor failures / robot malfunctions
Shortage of supporting materials: packing material, palettes, trolleys to name a few
No fault indication, when machine stops leading to confusion
Machine running without actual output (idling)
Shift change-over
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

7. TPM SPEED LOSSES Machine running slower than designed or desired speed
Process slowing down due to downstream limitations
Machine’s inability to withstand the designed or desired speed
Past experience
Fear of producing rejections
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

8. TPM
REDUCED YIELD
Too many stops & starts resulting in reduced stabilization period
Process limiting ramp-up & ramp-down time, reducing output
Up stream or down stream process limiting the ramp-up & ramp down periods.
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

9. TPM QUALITY REWORK & REJECTS
During every start-up (and sometimes, during stopping also), machine produces rejection
End product rejected due to various reasons
Rejection at customer’s site due to various reasons
Measuring system not consistent with process resulting in increased sampling quantities
Too many reworks before finishing the product
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

10. TPM How to calculate O E E ?
Open the attached excel-sheet object to calculate & understand O E E for two applications. Of course, once you understand the concept, it can be calculated to almost all applications
Certain parameters need to be measured and recorded for correctly calculating OEE. The measures could be obtained from production records, measuring instruments, machine control system. Correct parameters must be decided upon to calculate realistic OEE.
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

11. TPM How to achieve higher O E E ?
Start recording all the relevant data from production:
Planned hours
Actual run hours
Machine breakdown
Stoppages due to material, pallet change, shift change etc.
Quantity rejected in process, in inspection, at dispatch and possibly from customer’s end
Divide the data into various segments of Production, Maintenance & Quality
Start measuring O E E for 4 to 6 weeks continuously and study the weak links
Create small teams to work on individual weak links that contribute to O E E
Fine tune the data / targets from time-to-time
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

12. TPM Hidden benefits of O E E
Increase in productivity without huge monetary investment; of course time and people will be involved
All hidden losses will be made visible ensuring better clarity
Increase in profit margin of the company: Remember, O E E is one of the best methods of achieving profits without hurting the bottom line
Reduced customer complaints
Reduced breakdowns in machine
Last but not least, it saves power to the organization, since machines are run efficiently
Monday, April 22, 2019
Maintenance Circle
Maintenance Circle

13. Thank You TPM Monday, April 22, 2019 Maintenance Circle