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OEE Implementation

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Outline : PengenaIan OEE OEE Manufacturing Resep rahasia: I x F x A Studi kasus: OEE Improvement

The Power of OEE

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1. PENGENALAN OEE

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OEE (Overall Equipment Effectiveness) adalah cara "best practice" untuk memonitor dan mengimprove effectiveness dari manufacturing processes (i.e. machines, manufacturing cells, assembly lines).

• OEE adalah metriks terpadu yang mengukur tingkat yang dihasilkan dari suatu proses

Definisi OEE

Masurement adalah dasar dari improvement"

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Body Mass Index Kategori> 30 OBESITAS

25,0 - 29,9 OVERWEIGHT18,5 - 24,9 NOMAL

< 18,5 UNDERWEIGHT

Measurement create Crisis

mass(kg)BMI =

(height(m))2

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Major Losses

Losses Due To Machine

Breakdown

Losses Due To Set Up, Change Over

Losses Due To Deffect

Losses Due To Rework

Speed Loss Minor Stopage

“Berapa Resources Yang Terbuang”

Input : Machine Man

Power Material Energy

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Knowing your Losses is very valuable!

Losses adalah pemakaian resource yang tidak dirasakan oleh end customer tapi hanya menambah biaya produk

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Time Diagram

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Company OEEAwal Untuk OEE Umum 30% - 50%

World Class OEE 85% - 95%

World Class OEE

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OEE = Availability x Performance x QualityOEE Formula

OEE

Availability

Performance

Quality

Breakdown Losses

Minor Stoppage Scrap/Rework

Setup & Adjustment Speed Losses Start Up Six Big Losses

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2. OEE Manufacturing

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OEE & Lean ManufacturingBusiness Result

Return Of Stageholder EquityOperating Margin, Cash Flow

Operating Excellence

Continous Improvement

OEE – Operational Stability5R Stadndart Work, Maintenant Management

People Lean Processes

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Six Big Losses

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Model OEE OEE = Availability x Performance x Quality

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Perusahaan ManufacturingRunning Time = 8 JamBeakdown Mesin = 60 menitSetup Adjustment = 30 menit

Availability = (Actual Running Time / Planed Running Time) x 100%

= (8 Jam – (60+30 Menit) / (8 Jam)) x 100%

= 81 %

Contoh : Availability Calculation

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Avaiability Time = 8 Jam – 1,5 Jam = 6,5 JamTheoritical Speed = 120 Pcs / Jam Actual Output = 580 Pcs (Good+Reject)

Performance = (Actual Output/Theoritical OutPut) x 100%

= (580 Pcs/(120 Pcs/Jam x 6,5 Jam)) x 100%

= 74%

Contoh : Performance Calculation

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Actual Output = 580 Pcs (Good+Reject)Good = 500 PcsReject/Rework = 80 Pcs

Quality = (Actual Good / Actual Output) x 100%

= (500 Pcs/580 Pcs) x 100%

= 86%

Contoh : Quality Calculation

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Availability = 81%Performance = 74%Quality = 86%

OEE = Availability x Performance x Quality

= 81% x 745 x 86%

= 52%

Contoh : OEE Calculation

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3. Latihan Menghitung OEE

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Latihan Menghitung OEE

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Diketahui :

Total Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Theoritical Speed =2.000 Botol/Jam Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol

Hitung : Availability, Performance, Quality dan OEE ?

Hitung OEE Manufacturing

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Availability : (7 x 60) – (45 x 2) / (7 x 60) : 330 / 420 : 78,57 %

Performance : 6.300 / ((330/60) x 2.000): 6.300 / 11.000: 57,27 %

Quality : 5.900 / 6.300: 93,65 %

OEE : 78,57 % x 57,27 % x 93,65 % : 42,14 %

Jawaban Soal :1

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Diketahui : Running Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Cleaning Mesin = 20 Menit Theoritical Speed =2.000 Botol/Jam Idle menunggu Kemasan = 15 Menit Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol Jumlah Yang Bisa di Rework = 200 Botol

Hitung : Availability, Performance, Quality dan OEE ?

Hitung OEE Manufacturing

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How To Improve OEE

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Improve OEEInformation x Focus x Action

Result = I x F x A Terlalu Banyak Data, Tetapi Tidak Banyak Informasi

Tidak ada Informasi Dapat Berarti Keputusan dibuat Berdasarkan Insting. Ketiadaan Informasi menyebabkan tidak ada focus di perusahaan

Tidak ada Fokus utama untuk Improvment.effisiensi hanya menjadi sakah satu performance Indikator, tetapi belum menjadi sasaran satu perusahaan.

Tidak ada nya fokus menjadi penyebab tidak adanya alasan nyata untuk aksi.

Tidak ada aksi untuk mencapai sasaran bersama. Semua menjalankan bisnis as ussual (seperti biasanya)

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Accurate Data As Close to real time as you can get it Focusing On what caused you to be off track Review regularly and act !!!

Informasi Yang Tepat

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Collect Data pada banyak mesin, masalah produkstivitas,Tidak ada waktu - terlalu sibuk

Data tidak akurat :Tidak merekan minor StopMembulatkan angkaBudget Time

Karena data idak akurat, maka data tidak dipakai, sehingga operator tidak mengisi dengan benar.

Hasilnya : Tidak ada improvement

Issue menggunakan manual data collection

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Keuntungan Automated Data Collection

Manual System - Reaktif Automated System - Proaktif

Slow Reaktion Rapid Reaction

Historical Information Real Time

Snap Shot Audit Continous Visualization

Inaccurate data Accurate DataPerceived Losses On Critical Machine Real Losses on Critical Machine

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OEE Score Board (OEE DashBoard)

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