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Equipment can be best utilized by effective planning supported by the availability of RMPM.The IN and OUT movement must be planned to support the business. Manpower utilized is a challenge in KSA which can be achieved by rightsizing and continuous tracking of performance.
Resources like man power, tools and equipment can be rightly used with proper planning and prioritization of the jobs by the manager. Equipment utilization can be best achieved with the following :1. Right class and capacity of machine for the specified job,2. Efficient operator3. Close supervision
reduce and/or eliminate what are called the Six Big Losses – the most common causes of efficiency loss in manufacturing
Breakdowns,
Setup and Adjustments,
Small Stops,
Reduced Speed,
Startup Rejects,
Production Rejects,
BreakdownsEliminating unplanned Down Time is critical to improving OEE. Other OEE Factors cannot be addressed if the process is down. It is not only important to know how much Down Time your process is experiencing (and when) but also to be able to attribute the lost time to the specific source or reason for the loss (tabulated through Reason Codes). With Down Time and Reason Code data tabulated, Root Cause Analysis is applied starting with the most severe loss categories.Setup and AdjustmentsSetup and Adjustment time is generally measured as the time between the last good part produced before Setup to the first consistent good parts produced after Setup. This often includes substantial adjustment and/or warm-up time in order to consistently produce parts that meet quality standards.Tracking Setup Time is critical to reducing this loss, together with an active program to reduce this time (such as an SMED – Single Minute Exchange of Dies program).Many companies use creative methods of reducing Setup Time including assembling changeover carts with all tools and supplies necessary for the changeover in one place, pinned or marked settings so that coarse adjustments are no longer necessary, and use of prefabricated setup gauges.Small Stops and Reduced SpeedSmall Stops and Reduced Speed are the most difficult of the Six Big Losses to monitor and record. Cycle Time Analysis should be utilized to pinpoint these loss types. In most processes recording data for Cycle Time Analysis needs to be automated since cycles are quick and repetitive events that do not leave adequate time for manual data-logging.By comparing all completed cycles to the Ideal Cycle Time and filtering the data through a Small Stop Threshold and Reduced Speed Threshold the errant cycles can be automatically categorized for analysis. The reason for analyzing Small Stops separately from Reduced Speed is that the root causes are typically very different, as can be seen from the Event Examples in the previous table.Startup Rejects and Production RejectsStartup Rejects and Production Rejects are differentiated, since often the root causes are different between startup and steady-state production. Parts that require rework of any kind should be considered rejects. Tracking when rejects occur during a shift and/or job run can help pinpoint potential causes, and in many cases patterns will be discovered.
