OEE

Overall Equipment Effectiveness

Efectividad General de los Equipos
 OEE Definición

OEE - Efectividad General de los Equipos

Definición:
OEE es una medida que compara qué tan bien la fabricación
está funcionando en comparación con las condiciones perfectas
(Es decir, calendario perfecto, disponibilidad perfecta,
rendimiento perfecto, calidad perfecta).
OEE se calcula multiplicando los valores medidos
independientes del equipo

OEE = Tasa Calendario (SR)

X Tasa de Disponibilidad (AR)
OEE1
X Tasa de desempeño (PR)
OEE2
X Tasa de Calidad (QR)
 Que influencia el OEE?
Tasa Calendario (SR)
 Paradas Programadas
 Dias Festivos
 Almuerzo / Desayuno /
Descanso
 Almacén lleno (tanques)
 Parada programada (cambios
programados)
 Desarrollos
 Mantenimiento Preventivo
Tasa de Disponibilidad (AR)
 Tiempo perdido
 No hay Stock/No hay
Componentes
 Stock defectuoso
 Reuniones/Actividades turno
 Operador no disponible
 Lesionado / Enfermo /
LOAs
 Flexibilidad de
entrenamiento
 Escazes de operador
 Ausentismo
 Cambios de mas
 Mantenimiento Correctivo
 Paradas contabilizadas por
miscelaneos
 Falla de equipo
 Falla de herramientas o
falta de herramienta
manual
Tasa de desempeño(PR) Tasa de Calidad (QR)
 Paradas menores no  Rechazo de Arranque
identificadas  Scrap - Desperdicio
 Componentes atascados  Rework - Reproceso
 Sensor bloqueado
 Rechazo de producción
 No agregar a tiempo los
components  Daño en proceso
 Vencimiento cercano
 Pérdida de Velocidad
 Fuera de especificación
 Ineficiencia del operador
(agitar mas tiempo un
producto)
 Desgaste del equipo
 Girando a poca velocidad
 Calculation of Scheduled Rate (SR)

Total Available Time 1440 min / day

Holiday / Lunch / Breaks
Kanban Full
All Planned
Schedule Down
PM / Development
Downtime

Net Available Time

Total Available Time
is ALWAYS 1440 minutes.

We subtract: Planned Downtime

National or Local Holidays, Schedule Down, Full
Kanban, PM, Lunch & Breaks, Development ….

Net Available Time = Total Available Time – All Planned Downtime

Net Available Time

SR = Total Available Time
 Calculation of Availability Rate (AR)
Not Stock / No Components
All Unplanned
Defective Stock / Meetings Shifts
Change Overs Downtime +
Net Available Time

Unavailable Operator Change Over (C/O)

Breakdown Maintenance / Misc. Accounted for Stops

Net Operating Time

Net Operating Time – Is the time available after
the following are subtracted :
- Breakdown Maintenance
- No Stock/No Components
- Defective Stock and Code Changes
- Unavailable Operator
- Misc. Accounted for Stops

Net Operating Time = Net Available Time - All Unplanned Downtime

Net Operating Time

AR = Net Available Time
 Calculation of Performance Rate (PR)
Minor stops « Net operating time MUST be used to calculate
Speed losses the performance rate. The performance rate gives
Idles
us the information how well the machine is running when it
is running »
Net Operating Time

FACTORS THAT IMPACT PERFORMANCE RATE

Net Working Time

- Minor Stoppages
- Speed Losses – (Cycle Time changes)
- Idles
- Operator inefficiency
- Waiting on Maintenance

Net Working Time = Theoretical Cycle Time X Total Units Produced

Net Working Time

PR = Net Operating Time
 Calculation of Quality Rate (QR)
Defectives
Start Up Waste Scrap

SCRAP – includes all kinds of WASTE

- Start Up Waste
- Machine Waste

Good Units
Total Units
Produced

Produced
- Operator Waste
- Rework
- All Other DEFECTS

Good Units Produced = Total Units Produced – All Defective Units

GOODNetUNITS
Available Time
PRODUCED
QR = TotalUNITS
TOTAL Available Time
PRODUCED
 OEE – Overall Equipment Efficiency

1440 – 200 = 1240

1240 / 1440 = 86.1%
1240 – 200 = 1040
1040 / 1240 = 83.9%
833
200 min. All planned
1.4 min./tire * 600 tires = 840 min.
Downtime
840 / 1040=80.8%

200 min. 1040 – 840 = 200 min Loss

All Unplanned
Net Available Time 1240 Downtime + C/0 600 produced tires – 5 scrap = 595
Net Available Time

% of lost time
595 good tires / 600 tires produced = 99%
1440 Minutes

1440 Minutes
200 min.

Net Operating Time 1040

Util. And Effic.
Net Operating Time losses

Net Working Time

7 min. Scrap

Total Units

% of used
Produced

Good Units

minutes
Good

Produced
Units
595

X
(QR)
(SR)
X (AR)
X
(PR)
= OEE
OEE 1 = (SR) X (AR) X (PR) X (QR)
57.8% 86.1% X 83.9% X 80.8% X 99%

OEE 2 = (AR) X (PR) X (QR)

67.1% 83.9% X 80.8% X 99%
OEE - 8 Block - Example
• SUMMARY

• Leadership uses OEE to gauge performance.

• OEE2 numbers are reported monthly to Akron for ALL
processes.
• NA/Global leadership uses the OEE performance for
future planning/projects (such as HMC, T1XX).
• Production Specialists/Business leaders use the OEE
metric to attack bottlenecks/losses.
• Plant Optimization uses to track improvement to
processes on model machines and replicated machines
(DEC, RE).
• The OEEs 1 and 2 are used in plant capacity tools (such
as CvsR, PCCMT, RvCC) to calculate plant capacity and
capability.
• Capacities Calculations

Terminology Definition Formula

Avail. Time (1440 min) / Weighted

1 100% OEE Capacity Perfect Cycle (Theoretical)
average pure cycle time

Installed Capacity at Current equipment

((Avail. time * Max SR%* OEE
2 MAX SR
capacity under OEE2, 2%)/ pure Cycle time
considering all losses

Current equipment
Demonstrated capacity under OEE1, (Avail. time (1440min) * OEE 1)/
3 Capacity considering all losses at 3 Pure Cycle time
months run rate

Overall Equipment
4 OEE 1 Effectiveness
SR * AR * PR * QR

Overall Equipment AR * PR * QR
5 OEE 2 Effectiveness excluding SR
losses
• Capacities Calculations

• Pure Cycle Time = 39.6 minutes

• Machines = 184
• OEE 1 = 68.70%
• OEE 2 = 89.88%
• SR = 76.43 %
• Max. SR = 96.85 %

• 100% OEE Capacity = (Minutes Available one Day / Pure Cycle Time ) * Machines
• 100% OEE = (1440 minutes Avail. / 39.6 minutes) * 184 machines = 6,690.9 TPD

• Installed Capacity = [(1440 minutes Avail. * OEE 2 % * Max. SR % ) * Machines] / Pure Cycle Time
• Installed Capacity = [(1440 minutes Avail. * 89.88% * 96.85%) * 184 machines] / 39.6 minutes = 5,824.4 TPD

• Demonstrated Capacity = (Minutes Available one Day * OEE 1 %) / Pure Cycle Time
• Demonstrated Capacity = [(1440 minutes * 68.70%) * 184 machines ] / 39.6 minutes = 4,596.6 TPD