Overall Equipment Effectiveness Research Articles

A SEMINAR PAPER ON “OVERALL EQUIPMENT EFFECTIVENESS: A CASE STUDY AT A BOTTLING PLANT”

Overall Equipment Effectiveness (OEE) is the crucial tool of Total Productive Manufacturing (TPM). OEE evaluates the workability of the equipment in relation to its performance capacity provided that it should be operated in the optimal manufacturing conditions. It considers the whole manufacturing environment not merely the availability of the machine for performing the particular work, but also the efficiency of the product during the equipment availability together with losses in efficiency due to various factors such as yield waste, rework, scraps, etc. Such analysis provides a broad view of machine operation and manufacturing efficiency and assists to formulate efficient strategies to enhance the productivity of the manufacturing line. This paper implements the OEE tool to identify the root causes responsible for affecting system line efficiency. For this, a case study on a production line of VBNPL, one of the reputed beverage companies in Nepal working as the franchise of the international brand “PepsiCo. Int”, is done. Initially, the OEE of a single production line called “GRB 400” is calculated by recording the total planned breakdown, unplanned breakdown, and filler breakdown. Onwards, becoming specific the OEE of the Filler is computed and all possible reasons for the drop in the efficiency are identified, for instance falling of bottle, bottle burst, bottle jam, loose vent tube, etc. by using various techniques such as Pareto chart and Fishbone diagram. Finally, suitable recommendations are provided to mitigate the issues that hampered the efficiency of the production line.

PERHITUNGAN PRODUKSI OVERBURDEN DENGAN MENGGUNAKAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE) DAN NILAI OEE DARI EXCAVATOR KOBELCO SK-200

PT. Starindo Sakti Award is the place to carry out this research which is located in Pangandaran. This study uses the Overall Equipment Effectiveness (OEE) method to optimize mining equipment in achieving production targets for overburden stripping. Overall Equipment Effectiveness (OEE) is a method that has been accepted globally to measure the level of a company and the potential for improvement of the production process. Overall Equipment Effectiveness (OEE) aims to evaluate the performance of an equipment used in industry. The factors to be calculated on the OEE component are: Availability Factor, Utilization Factor, Speed ​​Factor, Bucket Factor, Overall Equipment Effectiveness (OEE) of Equipment. The results of the calculation of overburden production using the OEE method after improving working time by reducing standby time and increasing operating hours, the overburden production obtained from the Kobelco SK-200 excavator is 20,160.22 BCM. While the Overall Equipment Effectiveness (OEE) value of the Kobelco SK-200 excavator after repairs is 60%.

A Continuous Production Apparatus for a Frame-Type Melt-Blown Filter Cartridge with Various Properties and Geometry

Polypropylene (PP) melt-blown (MB) filter cartridges are widely used in many fields requiring water purification, such as households, the food industry, industrial processes, and recycled water filtration. While the demand for filters has gradually increased, the environmental requirements and conditions have become severe. The filters are easily deformed from higher liquid pressure during operation and setup and need to be replaced frequently. With the lifetime of filters shortened, manpower increases to replace filters. Hence, the inner structure of a PP melt-blown filter cartridge is supported by a frame structure to resist higher liquid pressure for enhancing filtration efficiency and lifetime. The filter, known as a “frame-type melt-blown filter cartridge”, does not affect the user’s application environment and equipment. This article focuses on developing continuous production equipment for frame-type melt-blown filter cartridges. The core technology of the equipment is the mechanism design for conveying frame tubes integrated with the MB process. The PP fiber is simultaneously melted and blown on the frame tube, and the frame tube needs to be pushed forward while rotating. This mechanism can independently control the fiber’s rotational speed and push speed. The rotational speed affects the surface density, fiber diameter, and porosity of the melt-blown filter cartridge, and the push speed affects the core diameter and weight of the melt-blown filter cartridge. In addition, there is a frame tube feeding device at the input end of the conveying equipment for continuously carrying the frame tube. Then, the finally formed melt-blown filter cartridges enter the cutting machine to trim a certain length to complete a frame-type melt-blown filter cartridge. The complexity of the operation is simplified by a human–machine interactive interface. A programmable logic controller (PLC) and a LabVIEW human–machine interactive interface are used to dominate the equipment. The Modbus communication protocol is adopted for connecting and communicating between PLC and LabVIEW. The interface can integrate and analyze the process data, including overall equipment effectiveness (OEE), total effective equipment performance (TEEP), loading time, utilization, performance, and yield. The entire production process of the frame-type melt-blown filter cartridge is optimized, and the traditional output of 1000 per day is upgraded to 1300. Overall, the processing speed is increased by up to 30%.

Thermo Valve Air Compressor Maintenance and Repair Using the Overall Equipment Effectiveness (OEE) Method in Maintenance

Production activities carried out every day can interfere with the effectiveness of the machine, one of which is the compressor, so that sometimes problems in the field are still often encountered, such as the piston drive motor not rotating, the compressor does not turn on and off automatically, corrosion (rust), melted capacitors, and many more. things that can happen beyond the operator's control. Due to these constraints, the authors decided to find out more and made direct observations at PT. INKA Multi Solusi Service, as well as studying good and proper machine maintenance so that the company's productivity does not experience a significant decrease. The research was conducted by direct observation and direct interviews with the maintenance department to find out the steps that are usually taken in solving problems. To determine the value of machine effectiveness based on the measurement of three main ratios, namely: availability, performance efficiency, and rate of quality, is carried out using the Overall Equipment Effectiveness (OEE) method. The conclusion that can be drawn from this study is that maintenance on the Ingersoll Rand MM160 type screw air compressor is carried out to maintain the condition of the compressor in a ready state for use in measuring the level of machine effectiveness using the Overall Equipment Effectiveness (OEE) method at PT. IMSS, starting from May – July 2022, where the highest percentage in May 2022 is 94% and the lowest in June 2022 with a percentage is 90%.

Defect Detection System on Stamping Machine Using the Image Processing Method

Quality products are very influential in creating profits for the company and are also closely related to the level of customer satisfaction. The higher the quality of the products produced by a company, the higher the satisfaction felt by consumers. The biggest challenge in the production process is achieving good quality with a product defect rate close to zero defect. Defects in the product are usually small. This is of course very difficult for workers to inspect each product for a long time. Thus, manual inspection is certainly ineffective and inefficient because humans have a saturation point and get tired if they work for a long time. Previous research on detecting defective objects using image processing has been carried out but has not been able to detect up to the shape and size, while in this study it can detect up to the shape and size. Therefore, to implement an automatic product defect detection system we will use image processing and RFID technology. Image processing is processing on the image using a computer so that the image quality becomes better and produces value information for each color. Image processing techniques consist of image conversion from RGB to grayscale, thresholding (binarization), and morphological operations (segmentation). While RFID is an identification method by using a means called an RFID label or transponder to store and retrieve data remotely This study aims to implement a control system on HMI and also a detection system on defect products using a visual inspection system with the aim of getting the machine effectiveness value. One method to get this value is the Overall Equipment Effectiveness (OEE) method. It is proven by implementing a visual inspection system that gets an accuracy rate of 95.97% to detect rejected products and optimize the OEE presentation value obtained. In this study, the implementation of the production monitoring system was successfully implemented with an average OEE value of 52.49%.

Implementing Total Productive Maintenance in Yemeni Company for Industry and Commerce (YCIC): Case Study

Purpose: The purpose of this research is to design fundamental base for continuous improvement in maintenance that serves improving machine’s reliability and raises the productivity, to fix strong products in the market with perfect quality and competitive price. Zero breakdowns, zero defects and zero accidents are the target to possibly improve productivity, save costs by reducing wastes and equipment longevity. Making the workplace is healthy organizational environment and better performance, increases the work team spirit by appropriate follow instruction of the implementation and mutual respect and understanding between managers and employees. Design / Methodology / Approach: The data were collected using questionnaire, company’s documentation, interview and observations for 6 months at the lines of the company. The assessment is based on the overall equipment effectiveness (OEE), productivity and profitability approach. Cause-Effect diagram and Pareto chart techniques were used for identifying the problems in the production lines. The 8 pillars and others worksheets of TPM are used for 6 months period. Finally, OEE and its indexes were used as measuring of success the TPM implementation. Findings - The suggested scheme was effective in increasing the overall equipment effectiveness from 48 % to 85 % over a 6 months period. The parameters of OEE were a direct orientation of improvements in equipment availability, performance and product quality by highly recommendation on the pillars of TPM. This work may have exploits on the consistency of TPM nature to improve maintenance scheme for a generic system. The tools and worksheets presented can be helpful to managers and operators. Originality / value: Total productive maintenance (TPM) is one of the numerous diagnostic/prognostic maintenance strategies have been employed in this study. This research has implemented an integrated OEE and its parameters/managers and normal labors in order to clarify the cause / effect to make action for the critical/chronic lines to remedy the low production. This is the first time that the TPM in this company has been placed and its impact is gained after that specific and short period.

PENGUKURAN OVERALL EQUIPMENT EFFECTIVENESS PADA PROSES PEMOTONGAN INDUSTRI FURNITURE

The sawmill machine is one of the machines highly used in the cutting process n furniture production at PT X. The sawmill machine used at PT X experiences various problems, including damage and damage repair time in more than 15% of the total production time. The event of machine failures also causes several impacts, such as low target achievement and non-uniform quality. The Overall Equipment Effectiveness (OEE) gets an average OEE value for the period January 2021 - June 2021 of 46.79%, which is still far from the ideal standard value of Overall Equipment Effectiveness, which is 85%. Factors that greatly influence the low value of OEE based on. The sixth significant losses analysis is rework losses of 17.48%, followed by breakdown losses and reduced speed losses, which both have a percentage of 16.12%. Meanwhile, for Set up and Adjustment Loss, Idling Minor Stoppage, and Scrap or Yield Loss, the portions are relatively small, less than 5%.

ANALISIS OVERALL EQUIPMENT EFFECTIVENESS PADA BARGE LOADING CONVEYOR (BLC) PT MITRA BARITO

A barge loading conveyor (BLC) is the main means of transporting coal (material handling) from the stockpile to the barge. Disruption of the conveyor which is driven by an electric motor results in the cessation of the coal shipping process, so performance and efficiency in its use must be ensured. The purpose of this research is to see the value of overall equipment effectiveness (OEE) on PT Mitra Barito barge loading conveyor (BLC), which will later be used as a basis for corrective actions and efforts to increase productivity. The method used in this research is a quantitative method where at this stage the value of overall equipment effectiveness (OEE) is calculated which includes three categories of levels of availability, level of performance, and level of quality. Where in looking at the causes of low OEE seen from the proportion of six major losses. The results showed that the average overall equipment effectiveness (OEE) value of 56.19% was considered ineffective because corrective steps still needed to be taken so that it could inhibit barge loading conveyor (BLC) activities. This is affected by slowdowns, tuning, and adjustments, as well as idling and mining stops with high loss proportion values.

A mathematical approach of evaluating sustainability indicators in milling of aluminium hybrid composite by different eco-friendly cooling strategies

The purpose of this study is to evaluate the sustainability indicators of aluminium hybrid composite material (AA6082 + 3wt%SiC+1wt .%MoS2) under different eco-friendly cooling strategies such as dry, MQL, LCO2, MQL + LCO2. A variety of social, economic, and environmental aspects of sustainability indicators such as Total cycle time (TTCT), productivity, Total machining cost (CT) Energy consumption (Ec), Carbon emission analysis (Cee), Cutting force (CF) and Surface Roughness (Ra) are considered in this study. A novel sustainable approach of overall equipment effectiveness (OEE) is included to evaluate the true productivity under different cooling environments. By comparing all the machining conditions, it was found that hybrid (CO2 + MQL) resulted the highest OEE as 95.63% and very low carbon emission of 0.6 kg-CO2 under higher cutting speed of 120 m/min and feed rate of 0.1 mm/rev at 1 mm depth of cut.

Overall Drilling Effectiveness: key performance indicator adapted for rock drilling

OEE (Overall Equipment Effectiveness) is a key performance indicator (KPI) widely used in performance analysis in the mining industry. The present study develops the ODE indicator (Overall Drilling Effectiveness) adapting OEE concept for the reality of diamond drilling. The product of availability, utilization and quality rates in the drilling process calculates ODE. Quality is defined by the quotient between recovered drill core metreage and total drilling advance metreage. ODE consists of a management numeric tool when confronted with productivity results and drilling equipment cost. In this case study of Pilar Mine, property of Jaguar Mining Inc., the 21% rate portrays the minimum acceptable ODE value considering the enterprise operational reality according to its geological, logistical and financial particularities. When the ODE rate approaches or exceeds this value, productivity increase and cost reduction per drilled metreage are noted. The adaptation of OEE concept and elaboration of ODE as a new performance indicator, intended directly for diamond drilling process, displays as a useful performance control tool. The utilization of ODE as a KPI provides the opportunity to manage operational productivity and financial performance simultaneously.

Feasibility Study of Monitoring of Particle Generation in Plasma Etching Process by Plasma Impedance Measurement

In plasma etching process at LSI mass-production line, the particles cause the decrease in the production yield and the overall equipment effectiveness (OEE). In this study, the particles, which originate from etching reaction product, are investigated under the condition that a gas shower type electrode made from the developed MgO-based ceramics is used and a Si wafer is etched by using SFSUB6/SUB gas. We have demonstrated that plasma impedance monitoring method can monitor the tendency of particle generation caused by the flaking off of the film deposited on chamber inner walls. This non-invasive measurement method can be easily applied to the process equipment at mass-production line therefore the results can contribute to improvement of the production yield and the OEE.

공정 로스 구조에 의한 가동률지표 모형 연구와 FOM솔루션 데이터 분석 방법

The aim of this study is to present a new and improved metrics model for measuring the operating rate data based on the loss structure during the manufacturing process and a study on the data analysis methodology. First, the loss structure is classified, analyzed, and presented. Subsequently, the overall equipment effectiveness (OEE) metrics based on the total productive maintenance (TPM) losses are presented and the applicability problem is analyzed. The total production effectiveness (TPE) metrics, which includes both the equipment efficiency and 4M efficiency factors in the calculation of its operating rate new model, is then presented to minimize the problems of OEE. And the man-hour effectiveness (MHE) metrics is presented for measuring the man-hour during manual work with structured man-hour losses. Finally, factory operation management (FOM), which is a solution based on 4M multi-dimension analysis methodology, is applied for the analysis of the operating rate data.

Reliability-Based Analysis of Main Propulsion Fuel Oil System Maintenance for Tugboats with Qualitative and Quantitative Methods

This study aims to analyze the maintenance of the main propulsion fuel oil system for tugboats using both qualitative and quantitative methods. The focus is on evaluating the reliability of the system and identifying potential areas for improvement. The research employs a combination of expert interviews, industry standards, and statistical analysis to provide a comprehensive overview of the maintenance practices in place. The goal is to enhance the overall performance and longevity of the main propulsion fuel oil system in tugboats. The study uses data on the operational time, failure time and frequency, the number of vessels served, and fuel system diagrams to analyze the system's reliability. Qualitative methods such as Failure Mode and Effect Analysis (FMEA) and Fault Tree Analysis (FTA) were used, as well as quantitative methods such as Overall Equipment Effectiveness (OEE), Markovian Decision Process (MDP), and reliability methods. The study found that the FO Purifier component was the critical component with a Risk Priority Number (RPN) of 294. The average value of OEE was 47%, lower than the standard of 85%. The MDP analysis showed a probability of 0.08 for mild damage and 0.46 for moderate to severe damage under steady-state conditions. The FO Purifier component had the lowest Mean Time to Failure (MTTF) value of 1658.50 hours. The study provides a graph of the reliability function against time, and recommends maintenance actions based on the MTTF and MDP.

On the relationship between human factor and overall equipment effectiveness (OEE): An analysis through the adoption of analytic hierarchy process and ISO 22400

In the industrial field, one of the most widespread KPIs is represented by the Overall Equipment Effectiveness (OEE), first introduced by Seiichi Nakajima within the Total Productive Maintenance (TPM) theory and aimed at identifying the inefficiencies of industrial assets. While OEE has been objective of several studies, the relationship between the Overall Equipment Effectiveness and the role of the human factor in achieving its high levels of values has not been extensively investigated. In recent years few scientific studies have investigated the relationship, showing that there is a link between OEE and human factors, even significant, but not clearly identified yet. In order to examine this relationship, our study proposes a framework to clarify the links between human factors, OEE parameters, the industrial sector, and the degree of automation. This framework is then validated through the application of the Analytic Hierarchy Process (AHP) methodology. As a result, 13 aspects related to the human factor were identified. Finally, the study provides practical guidance and implications for maximizing the outcomes of the investigation, with the goal of improving an organization’s overall manufacturing performance. By understanding the impact of the human factor on OEE, organizations can make informed decisions to optimize their operations and achieve higher levels of productivity.

Analysis Of Overall Equipment Effectiveness (Oee) And Determining Six Big Losses To Increase The Effectiveness Of Lb 02 Lath

Breakdown is one of the problems faced by the manufacturing company PT. Bakrie Autoparts which is engaged in the Disc Brake automotive component industry for four or more wheeled vehicles. There was a breakdown on the LB 02 lathe an average of 42.5 hours per month that exceeded the tolerance limit determined by the company which is 25 hours per mont causing the production target not to be achieved. Based on this, research is carried out which aims to calculate the Overall Equipment Effectiveness (OEE) value, determine the most dominant type of Six Big Losses, and provide suggestions for improvement efforts to increase the effectiveness of the LB 02 lathe. The results showed the average value of Overall Equipment Effectiveness ( OEE) lathe LB 02, which is 81.43%, then this value is included in the moderate condition which includes an availability rate of 86.80%, a performance rate of 94.15%, a quality rate of 99.70%. Equipment Failure Losss is the most dominant in influencing the decrease in the effectiveness of the LB 02 lathe with an average value of 8.40% with an influence percentage of 46.41%. Proposed improvements include checking the source and supply voltage every day before starting the production process, checking and replacing engine parts, especially belts once a week and every 3 months for replacement, and checking the condition of lubricating oil and coolant every day after the production process.
 Keywords: Overall Equipment Effectiveness (OEE), Six Big Losses, Breakdown.

Adoption of Total Productive Maintenance System in Nigerian Agip Oil Company Ltd (Case Study: Kwale Gas Recycling Plant)

Consideration of drudgeries inherent in maintenance management system in Nigeria industries would eliminate the tedium associated in the system and improve equipment availability. Here an attempt was made to assess the equipment maintenance practice in NAOC-Kwale gas recycling plant, using Overall equipment effectiveness (OEE) as quantifiable performance indicator to determine the effectiveness and availability of various types of pumps and other installed equipment in the plant. Maintenance records of the pumps provided data for the computation. The availability, performance and quality rate of the pumps were used to assess the overall effectiveness of the various pumps. The OEE value of 5.3% obtained confirmed that the current maintenance strategy and policy of the company is very much below standard and unacceptable. Hence, it is evident that using TPM will avert unexpected system failure through early faults detection; provide safety operation, reliability and equipment durability. Keywords: Adoption, Maintenance system, TPM, OEE, Reliability, Durability. DOI: 10.7176/IKM/13-2-03 Publication date: February 28 th 2023

Assessing the adequacy of transportation overall vehicle effectiveness for sustainable road transportation

Organizations in today’s supply chains strive for transportation activities optimization. However, transportation is a significant environmental impact activity. Particularly, road transportation is the highest emission rate source and the most widespread modality for last-mile delivery. In this context, the use of performance management tools, such as key performance indicators (KPIs), is a strategy to reach both economic-operative and environmental benefits. Among all KPIs, overall equipment effectiveness (OEE) is one of the most suitable KPIs to measure the utilization of an industrial asset. In the transportation sector, a variant of the OEE, known as the transportation overall vehicle effectiveness (TOVE), is used to define the performance of vehicle distribution activities, such as road transportation for last-mile delivery and urban logistics. Although TOVE is effective for evaluating vehicle performance in terms of administrative availability, operating availability, performance, and quality, the indicator does not take into the environmental impact related to road transportation activities. Literature has proposed several formulations to quantify transport carbon emissions, most of which are linear relationships to the distance travelled. However, these models are not suitable for assessing the TOVE performance of road transportation activities. This paper aims to compare the performance of last-mile delivery in terms of TOVE and carbon emissions evaluated with a distance travelled formulation in two different scenario systems. The comparison shows the inadequacy of TOVE in terms of environmental sustainability, as maximizing road transport performance while ignoring the environmental dimension excludes the minimization of CO2 emissions. Therefore, the foundation for future developments of TOVE for sustainable road transportation can be established from this divergence.

Applying Total Productive Maintenance for Machinery Failure Prevention and Optimal Performance

The functional Total Productive Maintenance TPM role of holding emergency and unscheduled maintenance to barest minimum and reduce the amount of reactive maintenance which affects productivity in terms of cost and performance; using Overall equipment effectiveness (OEE) as key quantifiable performance indicator to determine machinery performance as measuring tool. To achieve optimal level, industries should do the right thing; use Maintainability, Availability and Safety enshrined (TPM) policy and do it right by ensuring that right competences are available. Furthermore, applying the never-ending improvement cycle: Plan-Do-Check-Act (PDCA) alongside will enable identify problem areas, to apply the policy to avoid premature replacement cost, maintain steady production capabilities and prevent systems failure and its components deterioration. Keywords: application, maintenance, failure prevention, performability, productivity, safety. DOI: 10.7176/IEL/13-1-04 Publication date: February 28 th 2023

Maintenance Analysis of Sterilizer Machine Treatment at PT. Karya Tanah Subur (KTS) Using the Overall Equipment Effectiveness (OEE) Method

PT. Karya Tanah Subur (KTS) is a company engaged in the oil palm plantation and processing business located in Padang Sikabu Village, Kaway XVI sub-district, Aceh Barat Regency. The resulting production is crude palm oil CPO (Crude Palm Oil) or crude palm oil Palm Kernel (PK) and shells. In processing crude palm oil, the Boiling Station (sterilizer) is one of the most important machines, because if the sterillizer machine is damaged it will affect the production process of the factory. The purpose of this study was to analyze the performance of the sterilizer using the Overall Equipment Effectiveness (OEE) method by calculating the average Avaibility, Performance Efficiency, Rate Of Quality, and OEE values ​​from the performance of the sterilizer so that maintenance actions can be determined. Based on the analysis results, the average Availability is around 58.44%, Performance Efficiency is 80.77%, Rate Of Quality is 100% and the average OEE value on the Sterillizer machine is 46.43%, with these values ​​when compared to the international standards then it will be a fairly high difference..

Predicting the Impact of Product Type Changes on Overall Equipment Effectiveness Through Machine Learning

Nowadays, Industry 4.0 and the Smart Manufacturing environment are increasingly taking advantage of Artificial Intelligence. There are more and more sensors, cameras, vision systems and barcodes in the production area, as a result of which the volume of data recorded during manufacturing and assembly operations is growing extremely fast. The interpretation and processing of such production-type data by humans is no longer possible effectively. In the Big Data domain, machine learning is playing an increasingly important role within data mining. This paper focuses on the product change processes of semi-automatic assembly line batch production and examines the impact of product type changes on the Overall Equipment Effectiveness (OEE) and attempts to determine future values through supervised machine learning. Using decision tree technology, the effect on the OEE value can be predicted with an accuracy of up to 1%. The presented data and conclusions come from a real industrial environment, so the obtained results are proven in practice.