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1、1Design.Build.Ship.Service.Editor:EnglishTrainers:OwenChenDept:IEDate:2008.5.13OEETrainingBasic2TableofContents1.IntroductiontoFlextronicsOEEMethodology2.WhatisOverallEquipmentEffectiveness(OEE)3.WhyitisimportanttomonitorOEE4.Sixbiglosses5.HowtocalculateOEE6.Exercises7.ManualOEEReporting3OEEaDeeperU
2、nderstandingIntheperfectfactory,equipmentwouldoperate100percentofthetimeat100percentofthedesignedcapacitywithanoutputthatis100percentgood.Inreallife,however,therearemanyplannedandunplannedobstaclesthatpreventtheequipmentfromoperatingcontinuously.Theinabilityofequipmenttoreachfullproductivepotentialc
3、omesfromthetimelossesgeneratedbydowntime,speedanddefectcauses.Thesethreemajorcategoryoflossesarethefoundationforunderstandingtheeffectivenessoftheuseofourequipment.OEE(OverallEquipmentEffectiveness)isametricusedformonitoringandimprovingtheefficiencyofourmanufacturingprocessesbymeasuringlosttimeandlo
4、stproduction.TheaimofOEEistohelpintheidentification,classificationandsystematiceliminationofcommonsourcesforproductivitylosses.OEEmeasuresthelossesfromlinedowntimethataffectequipmentAvailability,speedlosseswhichaffectPerformanceagainstdesignedspeed,anddefectlosseswhicharetheresultofqualityproblems.F
5、ullyproductivetimeisobtainedaftersubtractingthetimeconsumedbytheselossesfromtheoriginalscheduledproductiontime.Calculatingtheoverallequipmenteffectiveness(OEE)rateisacrucialelementofanyseriouscommitmenttoreduceequipment-andprocess-relatedwasteswhichincreasecostbutaddnovalue.4OEE=AvailabilityxPerform
6、ancexQualityBydefinition,OEEistheproductofAvailability,PerformanceandQualitypercentages.Duringaregularworkday,weplanforsomeperiodswherenoproductionactivitymaytakeplacesuchaslunches,breaks,meetings,maintenanceorotherevents.Whentheseplannedeventsaffectequipmentuse,theyaresubtractedfromthetotaltimethef
7、actoryisopenforbusinessresultinginplannedproductiontime.Asthedaycontinues,theequipmentgetsaaffectedbyunplannedeventsthatpreventthemfrombeingfullyproductive.TheseunplannedeventsarecategorizedintoAvailability,PerformanceandDefectlosses,andeachisdefinedbytimelosseventswithspecificclassifications.TheSix
8、BigLossesdeterminethecategoryinwhicheveryeventwillbeassigned;thishelpsproductionpersonneltoidentifyandsystematicallyeliminatetheircauses.5Set-UpandAdjustmentIdlingandMinorStoppageReducedSpeedQuality:DefectsinProcess&ReworkReducedYieldEquipmentFailuresEasytomeasureLowimpactonprofitHighimpactonprofits
9、LaborMaterials/sparesOutsideservicesMaintenanceoverheadEquipmentProductionLosses(SixBigLosses)6TheSixBigLosses7AvailabilityTheOEEmetricfocusesmeasurementandimprovementopportunitieswithinthetimethatafactoryisopenforbusiness.ThismeansthatAvailabilityisbasedonthehoursthatthebusinesshasestimateditneedst
10、obeopenedtomeettherequiredcustomerdemand.Therefore,theeffectivenessoftheequipmentuserefersonlytothetimewithinscheduleddemand.AnothermetricscalledMUwillbeintroducedlaterwhichfocusesontotalmachinecapacity(24hours7days)againsteffectiveuseAvailabilityrequiresthatproductionpersonnelmakesadecisiononhowlon
11、gtowaitbeforecallingaproductionstopeventadowntime.Inanidealsituation,wewouldwanttorecordcausesofdowntimeeveryTAKTtime,sinceeveryTAKTaunitislost.However,inmostcases,TAKTtimeisinsecondsandrecordingformalinformationeveryfewsecondsisnotpractical.Thismakescleartheneedtoinvolvethestakeholdersanddecideonho
12、wmanyunitslostshouldbethetriggertodeclareastopeventarecordabledowntimeevent.IftheTAKTforaparticularproductis60seconds,thendecidingtorecorddowntimeanytimeaprocessstops5minutesormoremeansatleast5unitslost.Thisalsomeansthatwewouldhaveformaldatareflectingdowntimeeventsonlyoverthe5minutemark,andalltheeve
13、ntsrecordedwouldaffectAvailability.EquipmentFailures-Suddenandunexpectedequipmentortoolfailures,orbreakdowns,areanobviouscauseofloss,sinceanequipmentfailuremeansthatthemachineisnotproducinganyoutput.SetupandAdjustments-Mostmachinechangeoversrequiresomeperiodofshutdownsothatinternaltoolsorproductpart
14、scanbeexchanged.Thetimebetweentheendofproductionofthelastgoodpartandtheendofproductionofthenextgoodpartisdowntime.Thisdowntimelossoftenincludessubstantialtimespentmakingadjustmentsuntilthemachinegivesacceptablequalityonthenewpart.TheAvailabilitycategoryalsoincludesdowntimeduetomaterialshortagesoroth
15、ernon-qualityrelatedeventsthatcausethelinetostopproducing.Whileitshouldbeobviousthatduringmaterialshortagestheequipmentisavailabletoproduce,theresultingidletimeduetolackofmaterialsforcespoorutilizationoftheequipmentresource.Byincludingmaterialshortagesaspartofdowntime,theOEEmetricmakesvisibletheneed
16、toresolveanymaterialsrelatedobstacles.8PerformanceOncethelossesduetodowntimehavebeenexperienced,theremainingtimeshouldbefullyproductive.Thismeansthatproductsshouldbeproducedatspecificspeedsasdeterminedbyagreedtheoreticaloutputrates.However,thereareotherobstaclesthataffecttheperformancerates,andtheys
17、howupinmanyformsthatrequiregreatoperatorinvolvementtoovercome.IntheAvailabilityexample,datawascollectedonlyoverthe5minutemark,whichmeansthattherewillnotbeformaldatacollectedbelow5minutes.Thismakescleartheneedtolookatperformanceasanoperatorbasedimprovementopportunity.Theyareclosesttotheprocessandcang
18、reatlyhelpinidentifyingcausesforpoorperformance.IdlingandMinorStoppages-Whenamachineisnotrunningsmoothlyandatastablespeed,itwilllosespeedandobstructasmoothflow.Theidlingandstoppagesinthiscasearecausednotbytechnicalfailures,butbysmallproblemssuchaspartsthatblocksensorsorgetcaughtinchutes.Althoughtheo
19、peratorcaneasilycorrectsuchproblemswhentheyoccur,thefrequenthaltscandramaticallyreducetheeffectivenessoftheequipment.ReducedSpeed-Reducedspeedoperationreferstothedifferencebetweentheactualoperatingspeedandtheequipmentsdesignedspeed(alsoreferredtoasnameplatecapacity).Thereisoftenagapbetweenwhatpeople
20、believeisthemaximumspeedandtheactualdesignedmaximumspeed.Thegoalistoeliminatethegapbetweentheactualspeedandthedesignedspeed.Significantlossesfromreducedspeedoperationareoftenneglectedorunderestimated.9QualityLossesAdefectlossmeansthattheequipmentisproducingproductsthatdonotfullymeetthespecifiedquali
21、tycharacteristics.Thesedefectiveproductsconsumetimefromequipmentresourcesbutarenotavailabletothecustomerandwillconsumeadditionalresourcestoreworkthem.ScrapandRework-Lossoccurswhenproductsdonotmeetqualityspecifications,eveniftheycanbereworkedtocorrecttheproblem.Thegoalshouldbezerodefectstomaketheprod
22、uctrightthefirsttimeandeverytime.StartupLosses-Startuplossesareyieldlossesthatoccurwhenproductionisnotimmediatelystableatequipmentstartup,sothefirstproductsdonotmeetspecifications.Thisisalatentloss,oftenacceptedasinevitable,anditcanbesurprisinglylarge.10OverallEquipmentEffectivenessElementsThethreem
23、aincategoriesofequipment-relatedlosses-downtime,speedloss,anddefectorqualityloss-arealsothemainingredientsfordeterminingtheoverallequipmenteffectiveness.Overallequipmenteffectivenessiscalculatedbycombiningthethreefactorsthatreflecttheselosses:theavailabilityrate,theperformancerate,andthequalityrate:
24、AvailabilityRatexPerformanceRatexQualityRate.Thebodyofthisdocumentwillprovidethedetailsbehindeveryelement.ThegoalofmeasuringOEEistoimprovetheeffectivenessofourequipment.Sinceequipmenteffectivenessaffectsshopflooremployeesmorethananyothergroup,itisimportantthattheyareinvolvedintrackingOEEandinplannin
25、gandimplementingequipmentimprovementstoreducelosteffectiveness.Itisrecommendedthatoperatorsareinvolvedinthedatacollectionprocess.Collectingthisdatawillteachtheoperatorabouttheequipment,focustheoperatorsattentiononthelossesandgrowafeelingofownershipoftheequipmentTheshiftleaderorlinemanagerisoftentheo
26、newhowillreceivethedailyoperatingdatafromtheoperatorandprocessittodevelopinformationabouttheOEE.Workinghandsonwiththedatawillgivetheleader/managerbasicfactsandfiguresontheequipment,helphimorhergiveappropriatefeedbacktotheoperatorsandothersinvolvedinequipmentimprovementandalsoallowtheleadertokeepmana
27、gementinformedaboutequipmentstatusandimprovementresults.11WhatisOEE?OEEuGivesoperatorsafocusonlossesuTeachesoperatorshowandwheretheirmachinescauselossesOEEOEEuuGivesoperatorsaGivesoperatorsafocusonlossesfocusonlossesuuTeachesoperatorsTeachesoperatorshowandwheretheirhowandwheretheirmachinescausemachi
28、nescauselosseslossesTeamActivitiesuGiveabottom-upstructureforcontinuousimprovementuActivateshop-floorknowledgeTeamActivitiesTeamActivitiesuuGiveabottomGiveabottom- -upupstructureforstructureforcontinuouscontinuousimprovementimprovementuuActivateshopActivateshop- -floorfloorknowledgeknowledgeUsingtea
29、mactivitiestoimproveOEE=continuouslyimprovingequipmenteffectiveness!UsingteamactivitiestoimproveOEE=UsingteamactivitiestoimproveOEE=continuouslyimprovingequipmenteffectiveness!continuouslyimprovingequipmenteffectiveness!ItprovidestoManagerswithmeaningfuldatatomakerationalinvestmentdecisionsItprovide
30、smanagerswithmeaningfuldatatomakerationalItprovidesmanagerswithmeaningfuldatatomakerationalinvestmentdecisionsinvestmentdecisionsOverallEquipmentEffectiveness(OEE)isacoremetricusedtodetermineequipmentavailability,equipmentperformanceandprocessquality.12QualityMaintenanceAchievingandsustainingquality
31、bymaintainingequipmentandprocessesNewassetsmeetproductionneedsandminimizeLifeCycleCosts(LCC)EarlyEquipmentDesignandStartupManagementAttackSixBigLossesSGATeamfocusesoncontinuousreductionofproductionlossesbasedonfacts&dataSupportedby:AIWsKaizenOEEPlannedMaintenanceMovingfromreactivetoproactivemaintena
32、nceAutonomousMaintenanceAssetfocusedSmallgroupactivitiesassumesownershipfortheefficiencyoftheirasset(s)OnePlanOneTeamTPMSafetyHealthandEnvironmentalTrainingandEducationWheredoesitfit?13WhyMeasure?Identifylossesonaspecificasset.Providefeedbacktostakeholdersinvolvedinimprovementactivities,andaccuratel
33、yreflecttheresultsoftheimprovementeffort.Trackfacts&datatoensurerootcausesolutionstoproblems.Demonstrateimprovementvisually.Optimizeproductivecapacitybaseduponfacts&data.Useimprovementresourcestomaximizethebenefittoproductioncapacity.Enhanceabilitytoconvincinglytranslateimprovementsintothelanguageof
34、management($).14*Whatgetsmeasuredgetsfixed.*Ifyoudontknowwhatyourlossesare,YoucantfixthemWhyMeasure?15PlannedProductionTimePlannedProductionTimeActualProductionTimeActualProductionTimeDowntimelossesA1A1P2P2P1P1Q2Q2Q1Q1A1/A2xP1/P2xQ1/Q2TheoreticalOutputTheoreticalOutput(duringactualoperatingtime)(dur
35、ingactualoperatingtime)ProductionOutputProductionOutputSpeedLossMinorStopsProductionOutputProductionOutputQualityOutputQualityOutputScrapReworkTotalHoursAvailable(24/7)FlextronicsStandardTotalHoursAvailable(24/7)FlextronicsStandardAvailabilityRateQualityRatePerformanceRateOEE=HowtocalculateOEE(inanu
36、tshell)PlantOperatingTimePlantOperatingTime(Openforbusiness)(Openforbusiness)ClosedforBusinessPlannedDowntimeA2A2ALine,Building,orSitemaybeClosedforBusiness16DowntimeandOEE17Level1and2DowntimeCategoriesNote:TheseStandardizedDTCodesaretobeincorporatedintoFlexFlowwithOEEModule18Level3and4DowntimeCateg
37、oriesGOperatorrelated19TheAvailabilityformulatakesintoconsiderationtheUnscheduledDowntimeLosses,andiscalculatedas:Availability=OperatingTime/PlannedProductionTimeOEEAvailabilityFormula20ThePerformanceformulatakesintoconsiderationtheUnscheduledDowntimeLosses,andiscalculatedas:Performance=ActualCompon
38、entsPlaced/(LineTargetCPHxOperatingTime)Where:ActualComponentsPlaced=#BoardType“A”x(#componentsonType“A”)+#BoardType“B”x(#componentsonType“B”).nMPS =Business Segment70%ofManufacturersCatalogSpeedLineTargetCPH=sumoftheMPSsforallplacementequipmentintheline.ActualComponentsPlaced=TotalchipsandICsplaced
39、duringtheperiod.Or.MPS=MaximumProductionSpeedforeachmachinemodel(ONLYBasingonChipPlacementMachines&Heads).MobileConsumerDigitalAllOthers66%ofManufacturersCatalogSpeed60%ofManufacturersCatalogSpeedOEEPerformanceFormula21MPS =Business Segment70%ofManufacturersCatalogSpeedMobileConsumerDigitalAllOthers
40、66%ofManufacturersCatalogSpeed60%ofManufacturersCatalogSpeedStepstoDetermineMPSTarget:1.PerLineConfiguration,ONLYselectChipPlacementMachines&ChipPlacementHeads2.DetermineChipPlacementMachine/HeadCatalogSpeedbyequipmentvendor/modelrefertoMPStableSampleLineTarget(MPS)Calculation22SampleMPSSeparatefile
41、providedfortheMPSofallplacementmachines23TheQualityformulatakesintoconsiderationtheQualityLosses,andiscalculatedas:Quality=ActualGoodBoardsatICT/TotalBoardsProducedor.ifnoICTisintheprocessusethelasttestapplicabletotheproduct.Note:BasedonsiteprocessconfigurationOEEQualityFormula24FlextronicsOEEStrate
42、gyThepurposeofinvestingresourcesinmeasuringOEEistoimproveequipmentutilizationandperformanceinordertoreduceSMTcapexexpenditures.ThemostexpensivemachinesintheSMTlinearethecomponentplacers.ThereforethecomponentplacersarethefocalpointoftheSMTline.Whatdoesthismean?Maximumeffortmustbemadetokeeptheplacemen
43、tmachinesrunning.Thebalancingofallcomponentsmustbeoptimizedacrossplacementmachines.Theequipmentandprocessesbeforeandaftertheplacementmachinesmustbeoptimizedtokeeptheplacementmachinesrunning.TheFocalPoint25OEEisessentiallytheratioofFullyProductiveTimetoPlannedProductionTime.Inpractice,OEEiscalculated
44、astheproductofits3contributingfactorsOEE = Availability x Performance x QualityThistypeofcalculationmakesOEEaseveretest.Forexample,whenall3factorsareat90%,OEEwouldbe72.9%.ThefollowingtableshowsgenerallyacceptedWorldClassgoalsforeachfactorWorldwidestudiesshowthattheaverageOEErateinmanufacturingplants
45、is60%WorldClassOEE26ExampleOEECalculation27OEEandMachineUtilization(MU)ImplementingOEEmeansstrivingtowardavisionoftheidealmanufacturingsituation,avisionthatencompasseszerobreakdowns,zeroabnormalitiesandzerodefects.Thepathtothisidealsituationisaprocessofcontinuousimprovementthatrequiresthetotalcommit
46、mentofeveryoneinthecompany,fromoperatorstotopmanagement.Themeasureofwhetheranimprovementprocessissucceedingoftenrestsontheultimateresultoftheprocess:themoneyitmakesorloses.Thisseemsrational,sincemakingmoneyistheultimategoalofindustry.Thefinancialbottomline,however,provideslittleornostrategicortactic
47、alinformationaboutwhatisactuallygoingonwithintheprocess;thusitgiveslittlehelpinfocusingonthethingsweactuallyneedtodotoimprovetheprocess.WhileOEEprovidesagoodmeasureforhowwellaprocessorfactoryisutilizingtheequipmentwithinscheduleddemand,itdoesnotprovideasenseforhowmuchofthetotalequipmentcapacityitisc
48、onsuming.AtFlextronics,totalequipmentcapacityisdefinedas7days/24hours,andthisclearlyindicatesthatthebusinessgoalisnottosimplyutilizetheequipmentefficientlybutalsotoutilizeitcompletely.28MachineUtilization(MU)ActualOutput/(TotalTimexLineTargetCPH)MU=Theoriginalstatement,intheintroduction,saidthatinth
49、eperfectfactory,equipmentwouldoperate100percentofthetimeat100percentofthedesignedcapacitywithanoutputthatis100percentgood.Inessence,thefactorygoalistoensurethatcompanyassetsareproducingatahighlevelofperformance,whilethebusiness(sales)aimstosellequipmentcapacity.Anothermetricthathelpsmanagementunders
50、tandthelevelofcapacityconsumptionisMachineUtilization.MUhastwosignificantdifferencesfromOEE.Insteadofusingthetimethefactoryopensforbusinessaccordingtodemandasthebaseline,ituses24hours7daystodrivetheAvailabilitycomponent.TheotherdifferenceisthatitdoesnotincludequalitytocalculatetheoverallMUandfocuses
51、ondowntimeandperformancelosses.TheobjectiveofMUincombinationwithOEEistohelpmanagementassesstheneedfornewequipmentwhenafactoryenterscapacityrestrictionstoproducerequiredcustomerdemand.29October 9, 2007.OEEManualdatacollectiontemplateuserguide(V11071009)30ConsolidatesitesresultintoRegion/GlobalAnalyze
52、OEEperformanceSiteASMTOperationsLead/Sup/MgrreviewShiftActivityReportLineConf.ActualoutputRuntimeDowntimeTargetMPSICTyieldUploadtoFtpServerCORPFTPSERVERCreatereport,DashboardPerformance feedback with PDCA OEE improvement plan/actionsDataentryStdtemplateManufacturingPerformanceReviewSiteBSiteZUploadt
53、oFtpServerthruOEEDATAREPORTANDFEEDBACKFLOW31ImportantPointsAboutManualOEEReportingMPS =70%ofManufacturersCatalogSpeedMobileConsumerDigitalAllOthers66%ofManufacturersCatalogSpeed60%ofManufacturersCatalogSpeedThereportsstartattheSMTlinelevelandrolls-upLineBuilding(orBusinessUnit)SiteRegionCorporationT
54、hesitereporthasworksheetsforlines,buildings(orbusinessunits),sitesummary.Theroll-uptothesitelevelisdoneautomaticallyoncethespreadsheethasbeencreated.EachlinehasanMaximumProductionSpeed(MPS)ThisisthespeedthatthelineisexpectedtomakeinChipsPerHour(Cph)whenitisrunning.TheMPSforeachmachineisdeterminedass
55、omepercentageofthemanufacturerscatalogspeedasbasedonbusinesssegment.TheMPSofeachchip-shootingmachineissummedtocreatethelineMPS.ThelineMPSisenteredoncewhenthespreadsheetiscreatedandremainsunlessthechip-shootingconfigurationchanges.TheMPSofthelineismultipliedbythenumberofhoursruntocreatethetargetnumbe
56、rofcomponentsfortheperiod.TheTargetNumberofComponentsisthedenominatorintheperformancecalculation.Thenumeratoristheactualnumberofcomponentsplaced,bothchipsandICs.32AdditionalPointsAboutManualOEEReportingOnlyitemshigh-lightedinyellowneedtobeenteredoncethespreadsheetisestablishedMajorDowntimeCategories
57、 Closed for Business1 Planned (TPM etc.)2 Equipment (TPM hardware, software, program, fixture, feeders, etc.)3 Materials (kits not available to the line, wrong parts, short parts, etc.)4 Operations (meetings, people shortage, training, etc.)5 Changeover/Set-up6 Quality (time lines are down to resolv
58、e quality issues)ActualProductionOutputAPO = # of Board Type “A” x (# components on Type “A”) + # of Board Type “B” x (# components on Type “B”) .nQualityPassRate% Pass Rate at ICT or AOI or% Pass Rate at Functional Test33Buildinglevel(DoubleClickthistabandenterBuildingIDorBuildingnumber)SiteSummary
59、ReportFlextronicsMfgFiscalCalendar2008Templateformatwhenfileisopen34Step2:-SelectcellD101-Dropdownmenu-SelectRegion-SelectcellD102-Dropdownmenu-SelectSite-SelectcellD103-EnterreporternameandBusinessphonenumber-SelectcellD104-Dropdownmenu-SelectmonthofthereportOptional:Inputsitecomments,actionsorrema
60、rksinthisareaattheendofthemonth.Step1:Selectsheet“SiteSummaryReportInsertDatainYellowHi-LightedCellsOnlySiteSummaryReport35Step3:DoubleClickthistabandenterBuildingnumberorID.OnesheetforeachBuildingStep4:-Selectcell-EnterBuildingnumberandShiftPerday-Selectcell-EnternumberofTotalCP(ChipplacerinthisBui
61、ldingandHourPerShiftStep5:(Datacollectionlinelevel)-Selectcell-EnterSMTlinenumberorID#-Selectcell-EnterlineConfig.Equipmentdescription-Conveyorconnectbetweenm/c-EnterLineTargetMPSStep6:-EnterCloseofBusinessHrsfortheweek-EnterPlannedDowntimeHsfortheweek-EnterUnplannedLineDowntimefortheweek-EnterActua
62、lTotalplacementinthousandoftheweek-EnterQualityyield%InsertDatainYellowHi-LightedCellsOnlyBuilding(orBusinessUnit)andLine-LevelReport36ForMoreinformation,pleasevisitoureRoom:GlobalOverallEquipmentEffectivenessPleasejoinusintheOverallEquipmentEffectivenesseRoom!Justpointyourbrowsertothefollowingaddre
63、ss:s:/eroom1.flextronics/eRoom/FlexInternalFacility3/OverallEquipmentEffectivenessYourloginnameis:loginnameofrecipientwenthereIfthisisyourfirstFlextronicseRoom,pleaseprotectyouraccountwithapasswordassoonaspossiblebyusingtheabovelink.Otherwise,loginwiththesameloginnameandpasswordyouuseforotherFlextro
64、nicseRooms,orseeme.Werelookingforwardtoyourarrival!VishalPurangOEEeRoomCoordinator-EMCDocumentum:TheLeadingEnterpriseContentManagementandExtendedEnterpriseCollaborationSolution.Formoreinformation,see:/emc/documentum.s:/eroom1.flextronics/eRoom/FlexInternalFacility3/OverallEquipmentEffectiveness37OEE
65、DataAnalysisandCorrectiveActionsPlanOEECouncilNov.200738AnalysisCorrectiveActionClose-loopMethodology-EachtopDTcontributorrequiresupto3correctiveactions(seeREDHighlightsinDT2,3,4,5,6nextslide)-NeedtohavethedetailedanalysisandcorrectiveactionscompletedalongwiththereportsuponsubmittingtoCorp.-Eachsite
66、hasupto4workingdaystosubmittheMonthlyOEEreport&analysiswithcorrectiveactionsateachFiscalmonthend.-ForExample:-Nov.2007OEEreportmonthendonDec.1st,2007-OEEReportwithanalysisandcorrectiveactionisdueonDec.6th.,2007-Followupcallswillbesetupwitheachregion&sites39Oct.2007OEEData40BackupSlide41ThresholdDown
67、timeEarlierinthepresentationitwasnotedthatdocumenteddowntimeaffectstheAVAILABILITYelementofOEEandundocumenteddowntimeaffectsthePERFORMANCE.DocumentedLargerperiodsoftimethatarecategorizedaslevel1and2downtime:Planned, Equipment, Materials Logistics, Operations, Set-Up/Change-over, QualityUndocumentedS
68、mallerperiodsoftimethatarecontrolledbyoperatorintervention.Changing feeders, resetting machine faults, lack of TPM, machine/conveyance adjustment, etc.Machine or lines that blocked by excess WIP for small periods of time will fall into undocumented downtime also.ForeachSMTlinethesitemustestablishath
69、resholdlimitabovewhichdowntimeistobedocumentedandcategorizedintolevel1and2downtime.Itcanbebasedontimeoracertainminimumnumberofpieceslost.Takttimeforthetypicalproductrunonthelineshouldbeconsidered.Itisrecommendedthatline-sidedowntimerecordingformatsincludeacolumnforrecordingboththetimelostaswellasthenumberofpieceslosttoreinforcetheconceptoflostpieces.42Whyisthisimportant?TheImportanceofAccurateDTReportingHelpstheteamfocusontheproblemsolvingactivitiesthatcanreallyimpactthebusiness.NotproperlydocumentingdowntimewillnegativelyimpacttheperformanceelementofOEE.43Thankyou
