Page 103 - TPM A Route to World-Class Performance

84 TPM-A Route to World-Class Performance

Expected output in actual run time c = 1000 units in the 90 hours
Actual output d = 900 units
(owing to reduced speed, minor stoppages)
Expected quality output e = 900 units
Actual quality output f = 800 units

(owing to scrap, rework, start-up losses)

OEE calculation for an automated press line
Working pattern

0 Three shifts of 8 hours, 5 days per week
0 Tea breaks of 24 minutes per shift
Data for week

0 15 breakdown events totalling 43 hours
0 die changes averaging 4 hours each per set-up and changeover
0 15 500 units produced, plus 80 units scrapped, plus 150 units requiring
rework
0 Allowed time as planned and issued by production control for the five
jobs was 52 hours, including 15 hours for set-up and changeover
OEE for week

Loading time = attendance - tea breaks = 120 - 6 = 114 hours
Downtime = breakdowns + set-ups and changeovers
= 43 + 20 = 63 hours

Availability = - 63 = 44.7%
114
Actual press running time (uptime) = 120 - 6 - 43 - 20 = 51 hours

Allowed press running time = 52 - 15 = 37 hours
37
Performance rate = - = 72.5%
51
Product input (units) = 15 500 + 80 + 150 = 15 730
Quality (first time) product output (units) = 15 500
tz ;i:
-
Quality rate = - 98.5%
-
OEE = 0.447 x 0.725 x 0.985 = 31.9%