What is a Robust Manufacturing Process? Part 2.

What if you could transform your production facility into a model of efficiency? Join us as Matthew Woodford uncovers the secrets to achieving a world-class Overall Equipment Efficiency (OEE) of 85% or more! In this episode, Matthew simplifies the complex components of OEE, detailing how equipment availability, performance efficiency, and quality performance serve as vital indicators of a robust production process. By the end of this episode, you’ll be equipped with practical insights into minimizing variations and maximizing your facility’s output.

Matthew kicks off with a compelling explanation of how OEE serves as a benchmark for production health. He breaks down the calculation process for each OEE component starting with equipment availability, followed by performance efficiency, and concluding with quality performance. Learn how to measure operating time, planned cycle time, and the production of good parts versus rejects. This episode is packed with actionable knowledge that can help you assess and enhance the robustness of your processes, ensuring you meet the gold standard of production efficiency. Don’t miss this opportunity to elevate your manufacturing game!

The formulas referred to in this episode are:

• OEE = Availability x Performance Efficiency x Quality Rate
  • Availability = Operating Time / Net Available Time
  • Performance Efficiency = (Planned Cycle Time x Total Products Run) / Operating Time
  • Quality Rate = (Total Products Run – Total Rejects) / Total Products Run

Transcript

Matthew Woodford 0:07

Welcome back. My name is Matthew Woodford and I'm continuing my chat on breaking down and explaining what is a robust process. Hopefully you listened to the first part. I'm breaking it into several versions or episodes so you don't have to sit down and listen to it all in one go. In the first part we explained what is a robust process verbally. I want to quantify it.

Matthew Woodford 0:48

I ended off saying that OEE is a good indicator to understand the health of a production facility, overall equipment efficiency. Oee is a measurement of the ability of a machine to consistently produce a product which meets the quality standards at the designed cycle rate, without disruption. Without disruption. So we can use OEE as a measurement tool to understand what is the variation of our output. Because, if you remember, we said that a robust process needs to have minimal variation. Variation. So, if we use OEE, world-class standards would be aiming for a target of 85% or above. So if, when we do all our data gathering and our calculations, if our OEE is equal or better than 85%, we could then say yes, we have a robust process, easily said, not so easily achieved.

Matthew Woodford 2:21

First we have to understand what makes up OEE. How do I get OEE? Again, if you wish to learn OEE. There are many options available for you to take courses or read literature to understand the fundamental building bricks of an OEE system. But basically I will break it down Basically.

Matthew Woodford 2:51

Oee measures three key indicators. These, obviously the three key indicators, are made up of other such measurables to get to each of these indicators. But, as I said, I don't really want to be doing an OEE course here. Should you wish to do one, I'm sure you can contact myself or the company I am doing this chat for and you could be accommodated. But besides that, let's look Three key indicators Equipment availability, performance, efficiency and quality performance. If we have values of each of these key performance indicators, those will help us to understand where we are in OEE. Looking at these three key areas, we can therefore express that OEE is equal. To express that OEE is equal to availability, times, performance, efficiency times, quality rate.

Matthew Woodford 4:20

Ok, because we said the three key indicators of OEE were equipment availability, performance, efficiency and quality performance. So therefore the formula can be expressed as OEE equals A availability, p performance efficiency times, q quality rate. So availability, if we take the first key performance indicator there, availability is the amount of time the machine or process was available to run compared to the amount of time it was scheduled to run. It was scheduled to run. So therefore we can express availability as the operating time divided by the net available time. So, having understood what is the operating time, we divide it by the net available time. That will give me availability, the first part of my OEE indicator. So now we said OEE is availability. We found that it's operating time divided by net available time, but now OEE is availability times, performance efficiency. So how do I measure my performance efficiency?

Matthew Woodford 6:16

Performance efficiency determines how closely a piece of equipment runs to its planned cycle time. This can be affected by speed losses, as well as losses associated with undocumented idling or minor stoppages resulting from blocked or starved upstream or downstream equipment. If possible, this should be logged if it's having an impact on your key equipment performance efficiency. So these things you can understand and study if you wish to go deeper into OEE. But basically we would express performance efficiency is going to be equivalent to the planned cycle time times total production runs Divided by the operating time. So performance efficiency is fair to say that we need to understand the planned cycle time times total products run All divided by the operating time. That will give us our performance efficiency.

Matthew Woodford 7:37

The third key indicator is the quality rate. The quality rate is the total number of good parts produced on a machine or operation compared to the total products run. Okay, so how many parts were made in our production run? How many of those parts were good parts? So again, we can express our quality rate as equal to the total products run minus total rejects, all divided by the total products run. And when we look at total rejects it is not a good part. We don't want to know reworks. Then we start looking at things like first time through or FTT During the production run. How many parts were run, how many parts passed first time? So total products run minus the total rejects we're not saying scrap Minus total rejects divided by the total products run.

Matthew Woodford 9:01

Should you have attended our Core Tools 3, some of our students maybe projects or engineers, maybe listening then you can derive various data sheets that we discussed in order to capture all this supporting data to help with the above targets. But, as I said earlier, this is not about teaching oee, so if you do require further knowledge about oee, I'm sure you can find it. So this portion is just to summarize. A process should achieve 85% or more to be classed as a robust process. So if we are running an OEE 85% or more based on the formulas provided and you are achieving that, then that's well and done. 've got a robust process. It's never that easy, so next I want to focus on quality performance indicators. Until then, goodbye. Thanks for listening.