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Overall Equipment Effectiveness (OEE), Cycle Time and Plant Productivity

PARTICIPANTS

Mangers, Engineers who are responsible for: Production Lines & Plant Operations, Maintenance Planning & Follow Up, Production Planning & Scheduling, Workflow Studies, Time & Motion Studies

PROGRAM OUTLINE

  1. INTRODUCTION
  • Benefits of measuring Cycle Time, Productivity & OEE
  • Role of different parties in measuring & analyzing Cycle Time, Productivity & OEE
  • Measuring, analyzing and solving problems of Cycle Time, Productivity & OEE
  1. MATERIAL FLOW PRINCIPLES
  • Basic Definitions

Throughput / WIP turn rate / Takt Time
Cycle Time / Standby Time / Active & Passive Buffer
Work-in-Process WIP / Time to re-instate (TTR) / Rebatching
  • Material Flow Principles:

Conservation of Material Principle
Capacity Principle
Little's Law
Variability Principles
Variability Buffering Principle
Batching Principles
Serial Process Batching Principle
Parallel Process Batching Principle
  1. CYCLE TIME ANALYSIS
  • Total Cycle Time Concepts
  • Cycle Time Calculation with a Rework Loop
  • Cycle Time Analysis: Setup Time - Processing Time - Processing Times -Waiting Time Analysis
  • Cycle Time Efficiency
  • Cycle Time Management (CTM)
  1. PRODUCTIVITY ANALYSIS
  • Productivity & Operations:

The relation between Slitting Line Productivity, and: Net Productivity, Total Cycle Time, Performance Rate, Quality Rate (Quality Yield), Material Yield

  • Productivity & Production Planning & Scheduling:

The relation between Productivity, and: Uptime, Non-Scheduled Time, Scheduled Downtime, Utilization Factor, and Physical Availability

  • Productivity & Maintenance :

The relation between Productivity and: Mean Time Between Failures MTBF, Mean Cycles Before Failure MCBF, Mean Time To Repair (Recovery) MTTR, ……

  • Productivity & Cost :

The relation between Productivity and different types of Cost: Unit Cost, Hour Cost, Batch Cost

  1. OVERALL EQUIPMENT EFFECTIVENESS (OEE) & SIX BIG LOSSES

OEE = Availability Rate x Performance Rate x Quality Rate (Yield)

  • OEE calculation methods
  • Method 1—Using Nakajima formulas
  • Method 2—Using event time records
  • Method 3—Using product based calculations
  • World-Class OEE (according to Nakajima)
  • Total Effectiveness Equipment Performance (TEEP)
  1. SIX COMPONENTS OF MAINTAINABILITY
  1. Elemental Activities
  2. Malfunction Active Repair Time:

  • Preparation time
/
  • Part procurement time

  • Malfunction verification time
/
  • Repair time

  • Fault location time
/
  • Final malfunction test time

  1. Malfunction Repair:

  • Malfunction active repair time
/
  • Malfunction administrative time

  1. System Repair Time
  2. System Downtime:

  • System logistic time
/
  • System repair time

  • System final test time

  1. Total System Downtime is a combination of the distributions of

  • Initial delay
/
  • System downtime

  1. OPTIMIZING PRODUCTION LINE PERFORMANCE
  1. Effect of variability level on operating Curve
  2. Synchronizing the 4 M’s in production
  3. Determining Optimal Lot-Size
  4. Impact of dispatching rules on Production line performance
  5. Effect of Maintenance Strategy on operating Variability