What is Overall Equipment/Machine Efficiency (OEE):
OEE is the framework for measuring the efficiency and effectiveness of a process, by breaking it down into three constituent components (Availability, Performance and Quality product rate). It helps to measure a problem so that easily can fix it and provides a standardized method of benchmarking progress. OEE identifies the percentage of planned production time that is truly productive.
Overall Machine Efficiency
Overall machine or equipment efficiency is the how to performs machine versus spec. In practically,
OEE= Availability X Performance Rate X Quality Product Rate
Where,
Loading time – Down time
Availability = ………………………………………. X 100
Loading time
Standard cycle time x Processing quantity
Performance = …………………………………………………. x 100
Operating time
Processing quantity – Defective quantity
Quality product rate = ……………………………………………………………. X 100
Processing quantity
Let,
Working hours per day: 10 hours x 60 min = 600 min
Shut down (SD): 35 min
Loading time: (600-35) = 565 min
Equipment stoppage/ down time: (30+20+25) = 75
(a) Failure : 30 min
(b) Set up : 20 min
(c) Adjustment : 25 min
Operating time : (565 – 75) = 490 min
Standard Cycle time : 0.35 min/ pieces
Processing quantity : 550 pieces/ day
Defective : 30 pieces.
Now,
Loading time – Down time
Availability = ……………………………………………. X 100
Loading time
565 – 75
= ………………….. x 100
565
= 86.72%
Standard cycle time x Processing quantity
Performance = ………………………………………………….. x 100
Operating time
0.35 x 550
= ……………………. X 100
490
= 40.35%
Processing quantity – Defective quantity
Quality product rate = ……………………………………………………………………. X 100
Processing quantity
550 – 30
= …………….. x 100
550
= 94.54%
So, OEE = Availability X Performance Rate X Quality Product Rate
= 0.8672 X 0.4035 X 0.9454
= 33.08%
Low Machine efficiency rate due to man:
Management Losses;
Motion Losses;
Adjustment Losses;
Losses resulting from lack of automation and
Monitoring Losses.
Another topic:
Industrial Engineering:
Industrial engineering is a branch of engineering which studies the design and operation of production and service systems and the people who operate in these systems. Industrial engineering helps to improve quality and productivity. It is said that without industrial engineering operations is like meal without salt and if you use operation management instead of production management it will be best.
We can see at a glance of IE,
Industrial Engineering (IE) = Production ↑ Cost ↓ Proper use of all elements ↑ Efficiency ↑ Profit ↑
Some Important Formula for Industrial Engineering:
Some important formula of industrial engineering are given below for textile and apparel students and professionals.
Sum of average
1. Average time (in minute) = ……………………………………… ÷ 60
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑏𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛
2. Normal time = Average cycle time × Rating.
3. SMV =Observe time × Rating + Allowance.
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 ×O𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑆𝑀𝑉
4. Individual OP efficiency = ……………………………………….. ×100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 × 𝑆𝑀𝑉
5. Efficiency % = ………………………………………………… ×100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒 ×𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑋 𝑆𝑀𝑉
6. Performance = ………………………………………………..……………. X 100
(𝑀𝑎𝑛𝑝𝑜𝑤𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒)−𝐿𝑜𝑠𝑠 𝑡𝑖𝑚𝑒
𝐷𝑢𝑟𝑖𝑛𝑔 𝑖𝑛𝑡𝑒𝑟𝑣𝑒𝑛𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦−𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
7. Efficiency Improvement = ……………………………………………………..………… x 100
𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
8. Total labor cost saved per line = Extra minute produce × cost per SAM.
60
9. Worker potential production per hour = …………………………
𝐵𝑎𝑠𝑖𝑐 𝑚𝑖𝑛𝑢𝑡𝑒 𝑣𝑎𝑙𝑢𝑒
60
10. Individual worker target per hour = ……. × 𝑊𝑎𝑛𝑡𝑒𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑆𝑀𝑉
60
11. Line target per hour = ………… ×(𝑀𝑎𝑛𝑝𝑜𝑤𝑒𝑟 ×𝑊𝑎𝑛𝑡𝑒𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
𝑆𝑀𝑉
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡 𝑢𝑛𝑖𝑡
12. Defect of hundred unit (DHU) = ……………………………… x 100
𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛 𝑢𝑛𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡 𝑢𝑛𝑖𝑡
13. Defective % = …………………………………… x 100
𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛 𝑢𝑛𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡
14. Productivity each person per hour = …………………………………………. x 100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
𝑇𝑜𝑡𝑎𝑙 𝑢𝑛𝑖𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑏𝑦 𝑡ℎ𝑒 𝑙𝑖𝑛𝑒
15. Machine productivity = …………………………………………………………………..
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑒𝑛 𝑢𝑠𝑒 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑡ℎ𝑜𝑠𝑒 𝑔𝑎𝑟𝑚𝑒𝑛𝑡𝑠
𝑇𝑜𝑡𝑎𝑙 𝑆𝑀𝑉
16. Basic pitch time = ………………………………
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
𝐵𝑎𝑠𝑖𝑐 𝑝𝑖𝑡𝑐ℎ 𝑡𝑖𝑚𝑒
17. Upper control limit = …………………………………………
𝑊𝑎𝑛𝑡𝑒𝑑 𝑜𝑟g𝑎𝑛𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
18. Lower control limit = (Basic pitch time × 2) – 𝑈𝑝𝑝𝑒𝑟 𝑐𝑜𝑛𝑡𝑟𝑜𝑙 𝑙𝑖𝑚𝑖𝑡
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 – 𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
19. Cut of ship loss % = …………………………………………..…… ×100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝𝑝𝑒𝑑 𝑞𝑢𝑎n𝑡𝑖𝑡𝑦
20. Cut of ship ratio = ………………………………………. ×100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑢𝑡 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
𝑁𝑒𝑤 𝑐𝑢𝑡 𝑡𝑜 𝑠ℎ𝑖𝑝 𝑟𝑎𝑡𝑖𝑜−𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑟𝑎𝑡𝑖𝑜
21. Cut of ship ratio improvement % = …………………..…………………………..×100
𝐵𝑎𝑠𝑒 𝑙𝑖𝑛𝑒 𝑟𝑎𝑡𝑖𝑜
𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑖𝑝 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦
22. Receive to ship ratio = ………………………………………………………… ×100
𝑇𝑜𝑡𝑎𝑙 𝑓𝑎𝑏𝑟𝑖𝑐 𝑟𝑒𝑐𝑒𝑖𝑣𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑜𝑟𝑑𝑒𝑟 (𝑆𝑞.𝑦𝑑𝑠)
23. Total financial saving = Number of extra pieces shipped × Average FOB
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑒𝑥𝑝e𝑛𝑑𝑖𝑡𝑢𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑎𝑐𝑡𝑜𝑟𝑦
24. Cost Per Minute (CPM) = ……………………………………………………..
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑃𝑟𝑜𝑑𝑢𝑐𝑒 𝑡𝑖𝑚𝑒 (𝑀𝑜𝑛𝑡ℎ𝑙𝑦)
25. Cost of Manufacture (CM) = SMV × CPM
𝑇𝑜𝑡𝑎𝑙 𝑜𝑢𝑡𝑝𝑢𝑡 ×𝐶𝑀 𝑝𝑒𝑟 𝑔𝑎𝑟𝑚𝑒𝑛𝑡𝑠
26. CM earned per person per hour = ……………………..………………………….
𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑒𝑟 ×𝑇𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑚𝑖𝑛𝑢𝑡𝑒
27. Monetary Loss due to cut ship loss in month = (Total number of produced garments in month × cut to ship loss percentage for a month × Average FOB of the style)
28. Monetary Loss due to cut ship loss in style wise = (Total number of produced garments in the style × cut to ship loss percentage for a month × Average FOB of the style)
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑛𝑝𝑜𝑤𝑒𝑟
29. Man & machine ratio = ……………………………………
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑎𝑢𝑑𝑖𝑡 𝑓𝑎𝑖𝑙
30. Audit fail % = ………………………………….×100
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑎𝑢𝑑𝑖𝑡
31. Earned minute = Total production X SAM
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑑𝑐𝑜𝑢𝑛𝑡−𝑁𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
32. Factory direct & indirect ratio = …………………………………………………….
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
𝑇𝑜𝑡𝑎𝑙 𝑠𝑎𝑙𝑎𝑟𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑎𝑏𝑜𝑟 𝑖𝑛 𝑡ℎ𝑒 𝑚𝑜𝑛𝑡ℎ
33. Labor cost per minute = …………………..……………………………………….
𝑇𝑜𝑡𝑎𝑙 𝑆𝐴𝑀 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 𝑏𝑦 𝑡ℎ𝑜𝑠𝑒 𝑙𝑎𝑏𝑜𝑟𝑠 𝑖𝑛 𝑡ℎ𝑎𝑡 𝑚𝑜𝑛𝑡ℎ
𝑁𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑎𝑠𝑠𝑖𝑔𝑛𝑒𝑑 ×𝐻𝑜𝑢𝑟𝑙𝑦 𝑡𝑎𝑟𝑔𝑒𝑡 𝑞𝑡y
34. Estimated production per hour = …………………………………………………………….
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑛𝑜 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑖𝑛𝑢𝑡𝑒 𝑖𝑛 𝑎 𝑠ℎ𝑖𝑓𝑡 ×𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
35. Estimated machine productivity = ………………………………………………………..
𝐺𝑎𝑟𝑚𝑒𝑛𝑡𝑠 𝑆𝑀𝑉
𝑊𝑜𝑟𝑘𝑒𝑟 𝑝𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑃.𝐻 – 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑝𝑐𝑠 𝑃.𝐻
36. Productivity Gap % = ………………….……………………………………………………… ×100
…………
If you not undreastand you can reply in the comments. We are always your side. Don’t worry feel free to ask us. I hope that this article will be very helpful for a textile engineer. Wish you best of luck.
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http://www.downtimecollectionsolutions.com/