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Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness OEE

Powerful Productivity Metric

Overall Equipment Effectiveness (OEE) is a simple and powerful indication of resource effectiveness.  OEE is the ratio between ”value adding time” (what customers will pay for) and the actual total time taken (what the manufacturer pays for).  The purpose of OEE is to measure the productivity improvement potential of a production process using a single metric and to help minimise waste – the core objectives of Lean Manufacturing. OEE can be used to identify overall losses, and losses in these specific areas.  Once a loss has been identified appropriate action can be taken to reduce the loss.

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Understanding OEE and how to use it effectively

In this webinar recording, we talk you through the theory of Overall Equipment Effectiveness to help your understanding and ability to use it as an effective tool for improving manufacturing productivity.

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Diverse Team of Engineers and Managers sat at conference table discussing OEE dashboard metrics in Seiki AIR

Generating a standard measurement that can be used for benchmarking and analysis is an essential tool for any business. Recording data manually is a labour intensive and time-consuming activity. Seiki OEE calculations are based on access to logged records obtained from the machine tool to provide live and accurate data. This means that small events that are often missed or recorded inaccurately are taken into account, allowing you to base decisions on factual and complete information. Real-time OEE metrics are easy to calculate for fast production throughput, such as canning, packaging, PCBs.

OEE for Discrete Manufacturing

Whilst fully servicing the needs of process manufacturing, we’ve designed our OEE with the challenges of discrete manufacturing specifically in mind, i.e. when batch sizes are small, have long cycle times or you’re running diverse products with differing cycle times. To accommodate this level of flexibility and complexity, and still achieve an accurate measure of your OEE, you need to have all the underlying data for each factor, part and resource. This is where the power of our integrated modules come into play.

By calculating the Overall Equipment Effectiveness (OEE) of your existing assets, you can optimise their usage and reduce waste. This ultimately means reducing costs by avoiding unnecessary purchases and minimising downtime. An OEE figure combines measurements of machine availability, speed losses and the quality of parts produced to quantify how effectively that resource is being used.

OEE factors drill down

OEE Dashboards

The OEE Dashboards in Seiki AIR provide users with provide greater analysis flexibility and the ability to drill down into the contributing data of each OEE Factor.

Our OEE module combines data and insight from both Monitoring and WIP Booking to drive effective and sustainable improvements based on accurate data collected at point of event. It enables you to continuously tackle waste and losses across your entire process.

Availability Factor

Machine Monitoring provides visibility and analysis of the significant loss causing events that are having the biggest impact on throughput capability – your resource utilisation performance and potentially quick win improvement opportunities. Once you start to factor in Planned downtime events, you have all the data needed to calculate (and see) your Availability factor in OEE.

 

Performance and Quality Factors

Through digital work queues that are driven by works orders released from the Seiki Scheduler or third-party system, this module allows users to monitor live progress of jobs and capture the data required to identify any production time lost manufacturing individual parts, or Quality losses by booking non-conformances. For OEE, we use this data to compare the maximum theoretical speed that the operation can be run, versus the actual the production time. It’s also possible to drill down further and track Planned versus Actual performance across repeat works orders for a part within the system’s KPI reports.

Flexible Solution

Seiki AIR Monitoring is a pre-requisite to OEE as, once you start to factor in Planned downtime events, you have all the resource status data needed to calculate (and see) your Availability factor. To calculate the Performance and Quality factors of OEE, data related to Parts is required, and we’ve made it easy for you to get started with two solution options. In either configuration you will benefit from exactly the same, rich OEE analytics dashboards.

Seiki AIR OEE in a Monitoring Only System

Monitoring only OEE

Option one is to add an OEE license to a Seiki AIR Monitoring system:

  • Your team can administer Part and Operation records in AIR to define standard cycle times.
  • Operators search for operations from the Shopfloor OEE dashboard. They then confirm the start and completion, book part quantities and reasons for non-conformances.
Seiki AIR digital work queue

Monitoring & WIP Booking with OEE

Option two is to add an OEE license to a Seiki AIR Monitoring and WIP Booking system:

  • All the Part information required for OEE is inherent in the Works Orders released from the Seiki Scheduler or your existing APS/ERP system.
  • Operators are presented with a prioritised digital Work Queue for each resource. All WIP bookings are carried out directly on the panel of the active operation.
  • You will have access to additional Production History data that will allow you to drill deeper into planned vs actual performance, down to the individual operation level.

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