Overall Equipment Effectiveness, high performance gain and data analysis

Overall Equipment Effectiveness

Overall Equipment Effectiveness OEE is a “best practices” metric that identifies the percentage of planned production time that is truly productive. An OEE score of 100% represents perfect production: manufacturing only good parts, as fast as possible, with no downtime. OEE is useful as both a benchmark and a baseline:
- As a benchmark it can be used to compare the performance of a given production asset to industry standards, to similar in-house assets, or to results for different shifts working on the same asset; 
- As a baseline it can be used to track progress over time in eliminating waste from a given production asset (leanproduction.com, 2020).
OEE is a percentage metric (%) and is calculated by the simple multiplication of three factors:

Availability   X   Performance   X   Quality   =   OEE

Below we describe and detail every single factor that influences this important production indicator.

Factors having an impact on OEE

- Availability

In the production process, the proper schedule is designed for the operation of the machine. In case of any issue with the system, the plans and schedule suffer the most. In the planned production setups and adjustments, it is important to analyze quality inspections, maintenance, and cleaning processes. The unplanned stops in the production process reduce the system efficiency and breakdowns that result in a negative impact on the overall equipment effectiveness. Short periods and shortstops cause idle time instead of the production process. These issues come due to jams of equipment, misfeeds, and blocked sensors (Lachance , 2018)

- Performance

Performance is another factor that is applied to the production process when it does not run to full capacity. The issue could be due to poor maintenance of equipment, worn-out equipment, and operator issues such as errors, availability issues, and inexperience workers. In very simple words, the maintenance of the system or equipment is essential part of the development process and after development because the system user may feel or face several types of errors and ambiguities into the system. These types of the errors, defects as well as ambiguities may cause of the bad performance of the overall system or any specific component of the system. In the severe cases, the overall system may also crash or fail. To prevent such kind of problems, it is important to initiate the maintenance on the system. After applying or performing the maintenance for the system, all of the possible errors as well as defects will be removed from the system which will improve the overall speed of the system. The improvement into the speed of the system is the indication of the improved performance of the system (Lachance , 2018).

- Quality

Quality is a factor to analyze the defects and accuracy of production. In case of defects in the production, it reduces the accuracy and quality of the product. The possible errors could be batch changeover processes, operator error, long time run for short time production or vice versa, and wrong settings for the operation of the machines. To overcome such kind of problems, the engineering managers must have to design the process of the maintenance which will be initiated and performed after deployment of the system. But the quality is the major factor for the effective analysis of the errors and ambiguities into the system. The maintenance of the system will also provide improve the quality of the system including improve the quality of the system performance (Lachance , 2018).

Focusing on the Bottom Line
The cost of downtime will have the heavy influence on the profitability with the industry more focused on the bottom line. Furthermore, if the equipment initiates for wearing then it is possible to initiate the formation of the rejected parts as well as it does also not know this equipment for the long time. Ultimately, the system or equipment or any kind of software based system does not only affect the productivity, operations or the performance of the system while it also affect the quality of overall product. In the results of this condition, the customers of the systems or equipment will complaint more as compared to before. Furthermore, the nosedive will be taken by the market share later.

On the other side, many international companies in the world have already taken the maintenance approach and they are implementing the new model for the business service to change the systems of change maintenance within the solutions of the asset management. Therefore, the downtime is reduced by them as well as the ability to look ahead is also provided at the product quality before shipment through observing the machine wear, system or equipment as well as the overall performance of the equipment closely. The "run till failure" (RTF) strategy must be moved away by the engineering managers, and they have to adopt the predictive and preventive maintenance strategy because these kinds of maintenance management can easily save monetary resources of the company in the larger scale (OEE.COM, 2020).

Importance of Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness is significantly important in production potential optimization. OEE will increase the production process under the effective and efficient operation process and cost-effective methods. There are a number of ways to overcome the issues and these methods can be categorized into two types including short term methods and long term methods. The other possible alternatives are new shift, outsourcing production, increasing over time, new facility, and purchasing new equipment for the manufacturing process. the exceptional case is when maximum production yield is obtained and currently 85% overall equipment effectiveness score is considered as exceptional. The real situation is that many manufacturing facilities are far low than this level and they require significant improvements in the process and production to reach the level (Clarke, 2018).

5 Benefits of OEE in manufacturing
In the manufacturing process, the estimation of Overall Equipment Effectiveness yields a number of advantages. Some of the important conditions are listed below:

1. The analysis of overall equipment effectiveness ensures that presently existing equipment and working conditions are according to full capacity and maximum outcomes can be achieved in this way. This also enable to understand the ways to reduce the investment and to improve the outcomes;
2. The estimation of efficiency provides a vivid vision of the production process. In this way, it enables to measure the real issues existing in the production process and how they can be prioritized;
3. In manufacturing it delivers significant return on investment and increases the launching of new products, increasing capacity, and driving efficiencies;
4. Helps in maintaining the competitiveness in the market and improve the process quality of services with the saving of time and money. Also, it helps in maintaining a reputation in the market to avoid the risk and consequences of product;
5. The proper and timely checking of machines reduces repair cost and maintenance cost (OEE BLOG, 2016)

High performance gain and data analysis
In order to obtain high performance, it is important to consider all the situations such as improvement in the production line, condition - based management of services, machine testing, real - time monitoring of equipment and operations, and controlled mechanical and technological processes. The OEE improvement means storing, gathering, and analysis of data under these areas. Under the provided information, the management of companies can allocate the designed budget that improves the working efficiency of the company. The improvement of overall equipment effectiveness shows the higher achievement of objectives of the company and owners. The process involves providing products to customers, better value, and service improvement. In the technologically advanced system, the overall equipment effectiveness plays a key role in the development of the company for a leading range of products and customer solutions. The focus of services is on the reduction of customer operational cost and efficiency across the manufacturing process used in the company. The maintenance service is highly appreciated and recommended for the risk prevention and minimization because some of the risks can badly affect the activities at the workplaces. The system or equipment can face several issues during working or the system can also face issues after sometime of installation, then the maintenance of the system or equipment is necessary. Furthermore, every system or equipment installed in the organization, needs proper maintenance after some time of using the system for the better and improved performance (Iannone & Nenni, 2013) .

References
Clarke, P. (2018). OEE And Why It’s Important. Retrieved June 18, 2020, from https://slcontrols.com/oee-and-why-its-important/
Fit for Work. (2016). Maintenance of equipment in the workplace. Retrieved June 18, 2020, from https://fitforwork.org/blog/maintenance-of-equipment-in-the-workplace/
Iannone , R., & Nenni, M. E. (2013). Managing OEE to Optimize Factory Performance. Retrieved June 18, 2020, from https://www.intechopen.com/books/operations-management/managing-oee-to-optimize-factory-performance
Lachance , E. A. (2018). Understanding OEE Factors. Retrieved June 18, 2020, from https://blog.worximity.com/en/industry-4_0/understanding-oee-factors#:~:text=The%20three%20factors%20that%20contribute,Availability%2C%20Performance%2C%20and%20Quality
OEE BLOG. (2016). 10 advantages of OEE. Retrieved June 18, 2020, from https://www.sistemasoee.com/en/oee/89-for-dummies/107-10-oee-advantages
OEE.COM. (2020). OEE Factors. Retrieved June 18, 2020, from https://www.oee.com/oee-factors.html
LEANPRODUCTION.COM (2020) WHAT IS OEE? from https://www.leanproduction.com/oee.html