Detecting reasons for OEE loss:
How to do it
Is it easy to detection of reasons for loss of OEE? There are many ways to do it and all of them are valid but they must be regulated and correctly recorded. In addition, it is important to have a correct analysis to know and detect the losses.
The OEE (Overall Equipment Effectiveness) is a metric that measures the overall effectiveness of equipment in production. It is used to measure production and costs, and to identify opportunities for improvement in production processes. As you can see in our post on how OEE is calculated , it is calculated by multiplying availability, equipment efficiency and product quality.product quality. The goal is totive is to maximize efficiency and minimize downtime.
In short, OEE measures how much the equipment produces compared to its maximum capacity to produce a given item.In short, OEE measures how much the equipment produces compared to its maximum capacity to produce a given item. A decrease in OEE implies a loss of equipment efficiency, which can be caused by several reasons can be caused by several reasons:
- Micro stoppages and breakdowns: These are unforeseen events that stop production and require repairs.
- Planned downtime: Scheduled stops for maintenance or scheduled shutdowns for breaks.
- Product changeovers: Changeover time between one product and another can be lengthy and cause production delays.
- Speed losses: Equipment operates below its maximum capacity or at a slower speed than required for effective production.
- Quality defects: Products that do not meet established quality standards.
Factors affecting OEE
As you know, the OEE, is an indicator that measures the efficiency of a piece of equipment or a production plant production plant in percentage terms of the total output that should be produced in the same time.
To achieve high equipment efficiency, it is necessary to consider many factors that can affect performance and cause losses. For this reason, it is important to correctly detect reasons for OEE loss.
One of the main factors that affect OEE is the equipment downtimei.e. the time in which the machinery is not producing or is stopped. This downtime can be caused by a variety of reasons, such as machinery failure, scheduled maintenance, waiting for materials or lack of personnel, among others.
Another factor that can affect the efficiency of the equipment is the production cycle time, i.e., the time it takes for the equipment to produce the complete product. A long production cycle time means that the equipment is producing fewer units than expected per shift, which contributes to lower OEE.
Also, quality rate is a key factor affecting OEE.. When product defects occur, whether due to machine error or human error, it means fewer quality units are being produced, and therefore, efficiency decreases. Worse still, industrial, human, energy and material resources have been devoted to manufacturing defective product that is sometimes completely unusable and at other times requires cost overruns for reprocessing.
Finally, performance could be affected by the lack of operator training and qualification, as well as and training of operators, as well as the lack of adequate tools, machinery and technology.
In short, there are some main factors, in addition to those mentioned above, that have an impact on equipment efficiency, and it is important to analyze them one by one for the detection of reasons for loss of OEE. In this way, appropriate measures can be taken to correct and improve them.
Main losses in a factory
OEE as a tool is used to determine losses or leaks in the production process, which helps to identify areas for improvement and increase production efficiency. There are considered to be three main types of losses in a factory:
- Availability losses: refers to interruptions in the production process due to breakdowns, equipment failures or tool changes. This affects the availability of machinery and reduces production efficiency.
- Yield losses: this is due to inefficiencies in the production process, such as problems with production speed or product quality. It can also be related to problems in equipment adjustment or operator performance.
- Quality losses: this refers to losses associated with products that do not meet quality standards. This may be due to material problems, problems with production equipment or human error in the manufacturing process.
In general, the goal of measuring OEE is to reduce these three losses in a factory. By identifying these areas for improvement, companies can implement more efficient production strategies and practices to maximize production and minimize losses. By improving production efficiency, companies can increase their profitability and improve their competitiveness in the marketplace.
How to detect the reasons for OEE loss
The Team Effectiveness Index is an important tool for measuring the overall performance of a production team. This is how tracking OEE of OEE loss motifs:
- Analyze data: Collect all relevant data on the performance and efficiency of the production equipment. Analyzing this data will help you identify the type of losses that are occurring.
- Identify losses: Analyze and classify losses into the three categories: downtime losses, speed losses, and quality losses. This will help you identify the type of loss in equipment performance.
- Identify the reasons: Once you have identified the types of losses, you must drill down into each and identify the root causes. For example, if downtime losses are due to mechanical problems, you must identify the parts that cause problems and work on improving them.
- Assign priorities: After identifying loss reasons and root causes, it is important to assign priorities. This will allow you to work on the most important causes first, which will allow for a quick and significant improvement in the team's performance.
- Take action: Finally, you must take action to address the identified reasons for loss. Make sure that these measures are effective and that they are in line with the assigned priorities.
As a conclusion: the detection of OEE loss reasons is performed by collecting data, identifying losses, identifying loss reasons, prioritizing and taking effective action. This process is crucial to improve the efficiency and performance of the production line.
Assistant to Commercial Management at MESbook
Industrial engineer with more than 27 years of experience in different sectors as operations manager, Supply ChainProcesses and Quality. Lecturer at institutions such as the Chamber of Commerce and the General General Council of Industrial Technical Engineering of Spain.