OEE - Overall Equipment Effectiveness
Measure the OEE of a workstation with its three components, read it to identify the first loss to address, and avoid the practices that make the approach fail.
This course is intended for team leaders, methods technicians, maintenance managers and continuous improvement facilitators who need to set up or make reliable the measurement of OEE (Overall Equipment Effectiveness) on a workstation or a line. It assumes no prior training in Lean.
By the end, you will know how to break down a production day into six levels of time, distinguish the stoppages that are included in OEE from those that are not, calculate operational availability, performance rate and quality rate from the records of a workstation, then multiply them to obtain the OEE. You will know how to check the two prerequisites without which the figure is worthless (list of products, standard time per product), build a two-level loss tree, choose a recording method suited to the equipment and read the result to identify the first loss to attack. The course ends with the three practices that kill the approach: blame, comparison between different machines and the shop-floor average.
Each step takes about five minutes to read and relies on the same worked example, followed from start to finish: an injection press running on 2 shifts of 8 hours.
What you will be able to do
- Explain in one sentence what OEE measures and why it cannot reach 100 %.
- Break down a production day into total time, opening time, required time, operating time, net time and useful time, and state which stoppages are included in OEE and which are not.
- Calculate operational availability, performance rate and quality rate on a workstation from real data, then the OEE.
- Check the two prerequisites (list of products, standard time per product) and spot a standard time that is too slow and inflates the result.
- Build a two-level loss tree suited to a piece of equipment and choose between manual, semi-automatic and automatic recording.
- Read an OEE to identify the first loss to address, and avoid the practices that make the approach fail: blame, comparison between different machines, shop-floor average.
The path
- What OEE measures, and why 100% does not exist 4 min
- Breaking down the day: six levels of time, one boundary 5 min
- Calculating Do, Tp, Tq and OEE on real data 5 min
- The two prerequisites: product list and standard time 4 min
- Building the loss tree and choosing the recording method 4 min
- Reading OEE to take action, and the three uses that kill it 4 min
Prerequisites
No knowledge of Lean is required. You need to know a specific piece of production equipment (preferably your own): its operating hours, the products that run on it and an idea of its cycle rate. A calculator is sufficient for the exercises.
The closing quiz
The topic ends with a 8-question quiz, and a certificate is issued on success.