1 / 23

OE 3 Process “Overall Equipment Effectiveness Enhancement”

OE 3 Process “Overall Equipment Effectiveness Enhancement”. Background OE 3. Gap between engineered standard – perceived standard & actual productivity Based upon current observations, most manufacturers perform at 80% of their standard 80% is of perceived not engineered standard

wanda
Download Presentation

OE 3 Process “Overall Equipment Effectiveness Enhancement”

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. OE3 Process “Overall Equipment Effectiveness Enhancement”

  2. Background OE3 • Gap between engineered standard – perceived standard & actual productivity • Based upon current observations, most manufacturers perform at 80% of their standard • 80% is of perceived not engineered standard • Actual productivity is between 60-65% of engineered standard

  3. OE3 Productivity Measurement • Productivity can be measured in many ways (pieces per minute, pieces per hour, pieces per shift, runtime, downtime, tons per shift, tons per day, etc.) • All these Measurables are helpful and all can be misleading

  4. OE3 Productivity Measurement • Overall Equipment Effectiveness (OEE) • OEE is made up of three components • Performance – speed, SPM, GSPH, etc. • Availability – uptime, downtime, break time, runtime, etc. • Quality – good parts, bad parts, scrap

  5. What is OE3? • It is a top down and bottom up structured process that AFCo uses at a customer facility designed to improve operational efficiencies. • Management driven • The process is highly flexible & incorporates the following AFCo capabilities: • Equipment expertise • Continuous Improvement Experiences • Project Management Methodology • Team Process • Fresh set of eyes • A new look at your equipment and processes

  6. Concept of OE3 • OE3 is designed to compliment existing continuous improvement systems • Incorporates existing improvement ideas • No disruption of existing teams or processes • Utilizes short term (4-6 month) cross-functional teams with a targeted goal and event timeframe • Team resources matched to your operation • Events are integrated with equipment access • Can be used for large improvements or to assist in incremental improvements

  7. Basic phases of OE3 • On-site Customer Assessment • Leadership Team • Measurement Team • Improvement Team • Event I • Evaluation/Homework • Event II • Leadership Wrap Up

  8. Keys for a Successful OE3 Event • The event must have the full backing, support and involvement of senior level management • Goals must be clearly defined. What do you want to accomplish with this event? • Involvement from all levels throughout the entire event: maintenance, operators, supervisors, outside specialists, etc. • The three aspects of OEE must be addressed to achieve the necessary improvements. • Follow-up and use of visible measurables are necessary to maintain the improvement

  9. OE3 Team Process Begins with Leadership • Recognition of underutilized equipment or process • Have a desire to obtain improvement in equipment or process performance – not happy with status quo • Sufficient upper level management interest to conduct a Kaizen event to improve overall performance • Positive attitude that improvement is possible • Management must recognize that overall performance can only be enhanced by utilizing the team process • Use a leadership team approach to lead the process and follow-up

  10. Two Part Assessment First Part - Opportunity • Using your data, we will compare your current state (productivity) to what the engineered or possible future state would be.

  11. First Part – Opportunity(continued)

  12. Second Part - Environmental The environmental assessment is a highly subjective evaluation of an organization’s readiness to implement the OE3 process successfully. It is done over a 24 - 36 hour period with only a small sampling of input from a cross section of the organization’s personnel over all shifts. Based on the interviews and observations of the assessors general conclusions are drawn regarding the eight environmental parameters.

  13. OE3 Proposal • After the two part assessment a formal proposal is provided • A full list of services will be outlined • Possible opportunities identified • Deliverables determined

  14. Leadership Team • If customer feels the benefits of productivity improvement warrants our initiation of an OE3 program, a leadership team is organized based upon the corporation or plant leadership. This team would include AFCo and customer personnel.

  15. Leadership Team • Leadership Team charges the Measurement Team to collect information which will assist the Leadership Team in setting goals along with an event timeline.

  16. Measurement Team • The Measurement Team (normally made up of one or two customer supplied team members and an AFCo facilitator) either manually or assisted with a portable data collection device will gather and disseminate information that will be used to set goals for the Improvement Team(s).

  17. Improvement Team • The Improvement Team is formed and given the information and tools necessary to work on the steps to improve productivity based upon goals from the Leadership Team.

  18. Improvement Team • Improvement Team: • Event I: First of two kaizen events geared towards improving Productivity, Availability, Quality. Team members include: AFCo, the customer, customer suppliers. • Evaluation/Homework: An evaluation period to determine the effectiveness of the changes from Event I and to allow team members time to research additional opportunities for improvement. • Event II: The final kaizen event. • Leadership Wrap Up: A final report out of the results of the process.

  19. OE3: Benefits to the customer • Increased focus on teamwork. • Completion of general maintenance items/equipment corrections. • Access to equipment specialists • Savings realized due to efficiency gains. • Can be orchestrated in conjunction with a normal preventative maintenance machine calibration visit.

  20. OE3: Pilot Project • AFCo utilized test site to perfect the OE3 process from Sept 2007 to Feb 2008. • Results: • Test site reduced average Die Change time from 36 minutes to 13 minutes using team approach while eliminating several safety concerns. • Raised speed on 6 different high volume parts. • Pallet Change times on Side Out parts improved from 8 min. to 3.5 min. • Coil Change times improved from 13 min. to 7 min. with 3rd Operator.

  21. OE3: Pilot Project (continued) • Results(continued): • Improved the automatic centering of pallets on the stacker • Reduced downtime by installing jam detection • Automatic ram settings on the press • Improved quality by installing interlock on the stacker • Improved line restart function • Run speed of 2/3 total parts by an increased average of 33% • $700k-$1M bottom line savings for 2008 based upon equal volume

  22. OE3: Pilot Project(continued)Customer Comments • The Environmental Assessment that was conducted at the beginning of the process was very helpful in candidly assessing our weaknesses and exploring areas of improvement opportunity. • The OE3 Process engaged my team to set objectives and aggressively pursue them. • The structure provided by the OE3 facilitators was what we needed to organize our efforts and stay focused on our goals.

  23. OE3: Pilot Project(continued)Customer Comments • We focused on the “culture” of the plant as much as the “process” to get our results. • Our measurement period is not over but I can already see concrete and sustainable improvement from the OE3 Process.

More Related