Is it necessary for you to know the OEE of your production line at all times?
The ZPI OEE Calculator is a fast, simple and easy way to transform your Android Smart Phone into a portable six sigma workhorse. No more fumbling to calculate your Availability, Performance or Quality. Input metrics like the shift length, planned downtime and unplanned downtime, inputs, outputs and speed to calculate not only the OEE of the line but also the cost per OEE point breakdown. A must have for plant managers and supervisors.
The ZPI OEE Calculators offers:
Several Languages supported including: English, French and Spanish
Break down by hour or minute
Time and financial savings insight
Download today for Free!
It's not what you see… it's what you don’t. Gain insight, take action, improve manufacturing efficiency.
Access to live, accurate information is critical for making real-time business decisions to positively impact job profitability. Shoplogix's Plantnode Enterprise is the Performance Management System that provides actionable visibility & insight across shifts, jobs and the entire enterprise. With the Live OEE app you now have access to your key business metrics everywhere you go.
Learn more at www.shoplogix.com
Includes Downtime and Quality Pareto Charts for visualizing major losses in operation.
Overall Equipment Effectiveness (OEE) breaks the performance of a manufacturing unit into three separate but measurable components:
Availability Metric is a pure measurement of equipment uptime.
Performance Metric is a pure measurement of speed.
Quality Metric is a pure measurement of process yield.
1 unit = Production in single cycle(theoretical cycle time).
example 1: Production in single cycle = 10 MT
Total Production/shift = 100 MT
units produced = 100/10 = 10
example 2: Production capacity/cycle = 224 pieces
Total Production/shift = 2240 pieces
Units produced = 2240/224 = 10
example 3: Production capacity/shift = 500 square metre(here theoretical cycle time is shift time i.e.480 mins)
Total Production/shift = 250 square metre
Units produced = 250/500 = 0.5
Overall Equipment Effectiveness:
OEE breaks the performance of a manufacturing unit into three separate but measurable components: Availability, Performance, and Quality. Each component points to an aspect of the process that can be targeted for improvement. OEE may be applied to any individual Work Center, or rolled up to Department or Plant levels. This tool also allows for drilling down for very specific analysis, such as a particular Part Number, Shift, or any of several other parameters. It is unlikely that any manufacturing process can run at 100% OEE. Many manufacturers benchmark their industry to set a challenging target; 85% is not uncommon.
OEE = Availability Rate x Performance Rate x Quality Rate
The Availability portion of the OEE Metric represents the percentage of scheduled time that the operation is available to operate. The Availability Metric is a pure measurement of Uptime that is designed to exclude the effects of Quality, Performance, and Scheduled time loss.
Availability Rate = (shift hours - (personal allowance+cleaning time+management loss))/(scheduled hours - (breakdown time + job change loss + tool change loss + start-up loss))
Period(e.g.shift hours ) : 480 minutes.Other type of periods also can be entered but other parameters to be changed accordingly.
Personal allowance:Lunch time , Tea break , natural calls,etc.
management loss: Priority fixing Time, material flow time , etc.
scheduled hours = (shift hours - (personal allowance+cleaning time+management loss))
The Performance portion of the OEE Metric represents the speed at which the Work Center runs as a percentage of its designed speed. The Performance Metric is a pure measurement of speed that is designed to exclude the effects of Quality and Availability.
Performance Rate = (theoretical cycle time x Units produced)/(scheduled hours - (breakdown time + job change loss + tool change loss + start-up loss))
The Quality portion of the OEE Metric represents the Good Units produced as a percentage of the Total Units Started. The Quality Metric is a pure measurement of Process Yield that is designed to exclude the effects of Availability and Performance.
Quality Rate = good units/units started
good units produced <= Units produced <= units started.
good unit : fit for use
The app offers basic OEE calculation by specifying the availability, performance and quality losses. For more advanced and automated OEE measurement, analyses and reporting see our other product, the OEE Toolkit (www.OEEToolkit.com).
OEE uses the elements of Availability, Performance and Quality to provide a balanced efficiency score.
The LEAN OEE Tracker, courtesy of Growth Improvements Pty Ltd, will allow you to track 10 machine / product combinations, calculate your OEE, compare your efficiency score against the World Class Benchmark, email (excel based) data reports for your trending and graphing analysis and also work out the annual financial Lost Opportunity of running your machinery with the specifications you enter.
The LEAN OEE Tracker could put you on the right path to recovering hundreds of thousands of dollars.
APP User Instructions:
Step 1: Identify what the ‘Value Add’ activity is for your machine (the function the customer pays for).
Step 2: Create a machine and enter shift working time, machine performance and product financial figures. Use ‘60’ as a default in Value Add production (as in maximum of 60 minutes per hour Value Add Activity).
Step 3: Enter the Availability for a shift, either in Hours or Minutes. Enter the Equipment Operating Time for the shift ie. 6.75 hours.
Step 4: Enter the Performance for the shift, being the average performance of the Equipment per hour of Operating Time, in Units Produced, Machine Speed or as Value Add Production.
Step 5: Enter the Quality for the shift, being the amount of production output that was ‘Right First Time’, either in Units Produced, Scrap Rate or Yield Losses.
Step 6: View your Overall Equipment Efficiency for the shift, and the gap between your performance and World Class OEE standard (85%). Email report now, or go back to Dashboard to save data.
Step 7: View your annual financial Lost Opportunity, if the machine was run that way every shift. Often best to track a month’s data to find the average figures, enter them, and view a more accurate Lost Opportunity.
Step 8: Commence problem solving to recover some of that Lost Opportunity. Set a SMART Target to work towards, for OEE in the future.
Step 9: Visit http://growy.com.au/lean-oee-tracker/ for detailed instructions on how to tailor to App to your business, to get a free OEE Tracking Template, or business improvement assistance in general.
★ Use this application to:
- deploy Lean Manufacturing: tool by tool, area by area, by a business approach,
- continuously treat production data on workplace, in collaboration with operators.
★ Deploy Lean Manufacturing around these pillars:
- visual management,
- standardization of operations,
- production leveling.
★ The “Deploy” part consists of practical explanations, illustrated by many drawings:
- Determine where you should start your continuous improvement approach
- Make work environment cleaner and safer
- Develop communication tools through a visual management
- Calculate time really available for manufacture
- Identify and eliminate wastes of Value Added
- Adjust production cycle on the need of customer through Takt time
- Assign resources strictly necessary for manufacture
- Reduce your changeover time
- Build a Kanbans schedule to manage workflow by Just-In-Time
- Sustain Lean through a structured approach
★ Calculate easily major indicators of Lean: Required Time, Net Time, Fully Productive Time, Availability Rate, Quality rate, OEE Overall Equipment Effectiveness, Average Daily Demand, Takt time, Resources, Kanban.
★ Send data (collected and calculated) by email.
★ No particular knowledge is required to use this application:
- Lean beginners will appreciate: road map to self deploy Lean, topics that may be read independently, explanations with lot of drawings, calculators for main Lean indicators, send questions to authors;
- Lean experts will appreciate: materials to use on workplace, concrete examples.
★ Improve this app: if you want more information about a topic or if you want information about a new topic, contact us: firstname.lastname@example.org.
★ Please, update this app to fully benefit of new topics, bug fixes or performance improvement. This app is updated regularly.
★ Keywords: 5M, 5S, Continuous improvement, Demand Flow Technology, Gemba, Heijunka, Hoshin kanri, Jidoka, Just-In-Time, Kaizen, Kanbans, Lean Manufacturing, Net time, OEE Overall Equipment Effectiveness, Muda, Mura, Muri, PDCA, Quality rate, Resources, Six Sigma, SMED, Standardization, Strategy deployment, Takt time, U-cell, Value added, VSM, Wastes, world class.
Please contact FullFact at sales@FullFact.com or visit our website at http://www.oeetoolkit.com for more information on our products.
Please note that this app requires the OEE Toolkit with RemoteCollect and the web dashboard 1.6 to be installed. When no OEE Toolkit installation is configured, example machines and data is shown to illustrate what features the application offers.