Examples from industry. KPP202 Antti Salonen

Size: px

Start display at page:

Download "Examples from industry. KPP202 Antti Salonen"

Samson Logan
6 years ago
Views:

1 OEE improvement Examples from industry KPP202 Antti Salonen

2 Example: Case 1 Automatic assembly of contact blocks. Theoretic capacity ca 650 blocks/h. 5 m 5 m

3 Data collection Operations journal, managed by equipment operators Order Quantity Date Starttime Endtime Changetime Quantity defects Service (hours) Lack of Material (hours) Other stops (hours) Sign.

4 OEE OEE KB w % 90% 80% 70% 60% 50% 97, 5% 40% 30% 20% 82, 8% 84, 5% 70, 4% 57, 9% 10% 0% Planning f actor Availability Per f or mance r ate Quality OEE

5 Data collection: Unplanned stops Stop Fault description Corrective actions Start Date Time Sign. Date Time Sign.

6 Pareto: stop categories Stop causes: KB Marking Fixed contacts Long spring Other Step conveyor Lack of material Station 7 Short spring Packing Station 13

7 Data collection, short stops Station 0-6 min min min

8 Pareto: short stops Short Småstopp stops KB w Stegbalk Station Antal Quantity

9 Root causes: stn 7 Wrong measure on spring Station 3 Long spring not in place Motor not running Assembly method Counter cylinder to fast Short spring falls out Station 7 Stops or rejects Short spring not in place Wrong measure on spring Contact moves the spring Contact get stuck in feeder Moving contact not mounted Station 4

10 Development stn. 7 Moving Kontaktförare contacts Antal Quantity kontaktblock produced Qty Antal rejected felaktiga moving kontaktförare contacts Felprocent Percent rejects kontaktförare % December Januari Februari Mars 12% 10% 8% 6% 4% 2% 0%

11 2,50% 2,00% 1,50% 1,00% 0,50% 0,00% Result: short stops W603 w Stegbalk

12 Development, OEE TAK KB 100% 90% 80% 2,1% 27,9% 1,2% 24,3% 0,7% 13,3% 11,0% 0,5% 0,2% 10,0% 7,1% 7,3% 15,0% Kvalitetsförluster Quality loss Hastighetsförluster Speed loss Stillestånd Unplanned stops 70% 10,1% Effektivitet Effectiveness 60% 15,1% 50% 40% 75,0% 82,2% 77,7% 30% 55,0% 64,3% 20% 10% 0% January Januari February Februari March Mars April May Maj

13 Profitability Estimated cost: 40000:- Yearly saving: >600000:-

14 Example: Case 2 Surface mount assembly of PCB. 3 m Screen print High speed mounting Precision mounting Melting owen 20 m

15 Data collection 48 hours Two persons per 12h shift Stop watch 8 categories of stops Minor stoppages included

16 Data collection Category Time (Minutes) Note 2 24 Low pressure, solderpaste 7 12 Feeder error 8 2 Cleaning of print screen 8 1 Cleaning of print screen 3 3 Feeder refill 3 2 Feeder refill 3 21 Feeder refill

17 Result Time measured: 48 h Total stop time: 30,3 h Availability: 36.8 %

18 Stop categories Stop causes 9 8 Very rare failure Hours Component refill Shaft damage Set-up change Feeder error Other Software error Meeting PM

19 Adjusted result Time measured: 48 h Total stop time: 22,5 h Availability: 53,1 %

20 Refilling feeders Method Man Management Lack of routines Lack of competence Lack of responsibility Lack of instructions Lack of motivation Lack of systems view Lack of method development Lack of systems view Time loss Refilling feeders No material in workshop store Malfunctioning barcode system Too many component types Non taped components Machine Material

21 Refilling feeders Suggested improvements: New routines to secure that components are available in shop storage. New routines to secure that components get taped. Educate more operators how to tape components. Estimated reduction of time loss: %

22 Change over Method Man Management Lack of routines Lack of competence Lack of responsibility Lack of instructions Lack of motivation Lack of problem insight Lack of foresight SMED not performed Malfunctioning barcode system Lack of man power No material in workshop store Time loss Rigg change Rig equipment in bad condition Too many component types Machine is difficult to rig Non taped components Machine Material

23 Change over Suggested improvements: New SMED based rig procedures to minimize down time. Assignment of storage personnel for preparing new rigs. Estimated reduction of time loss: %

24 Robot cell for machining of gears Example 3

25 One week s measurements Kuggfräs, Tillgänglighet % Scheduled time Waiting for Change over quality assurance Small stops Failures Other Available time

26 Real failure data Jämförelse KG1 KG2 Milling: -MTBF: 113,25h -MTTR: 6,01h Grading: -MTBF: 117,4h -MTTR: 3,0h A sys : 92,6%

27 Adjusted graph Jämförelse KG1 KG ,0% ,0% 8,0% 70 2,4% 0,6% % Scheduled Schemalagd tid Kvalitetskontroll Waiting for Failures AU Omställning Change over Småstopp Small stops Kassationer Scrap Available Effektiv time tid time quality assurance

28 OEE in Swedish industry OEE Interval 50 % Average: 60% Possible improvement 88% Practical achievable goal 80% 20 Manufacturing industry 10 P&P PCB Power Ref. Mining Steel OEE %

Dependable production OEE, TPM, and RCM

Dependable production OEE, TPM, and RCM Antti Salonen antti.salonen@mdh.se How a production shift may look! Productive time Unproductive time Planned production time Start-up problem Set-up Break-downs