OEEOLE Training Package .ppt

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1、New Productivity Indicator-OEE&OLEOEE|OLE Symposium-hhyeo-122007-01To identify and establish new productivity indicators to-measure our true manufacturing effectiveness and efficiency-provide indication of areas to be focused on for continual improvement ObjectivesOEE|OLE Symposium-hhyeo-122007-01Th

2、e current“Productivity”formula:Effective HoursManufacturing Hours AvailableEffective Hours=Actual Output/Run RateManufacturing Hours Available is time after discounting the break timeRun Rate is determined by ME(PCBA)or IE(BB)as the“Best Optimized”run rateThis“Productivity”indicator is used for both

3、 PCA and DF/MA manufacturingCurrent Productivity Measurement OEE|OLE Symposium-hhyeo-122007-01Current Productivity Measurement Example:OEE|OLE Symposium-hhyeo-122007-01Current Productivity Measurement Example:Double the DL,equipment and time spent to get 10%additional output Productivity now becomes

4、 100%OEE|OLE Symposium-hhyeo-122007-01Shortcoming of the current“Productivity”measurement:focus only on achieving the targeted run ratedisregard the manufacturing resources used to achieve the targetdoes not indicate area to focus on for improvement if the target did not achievedCurrent Productivity

5、 Measurement OEE|OLE Symposium-hhyeo-122007-01Definition of ProductivityProductivity shall be determined by looking at the production obtained(effectiveness)versus the invested effort in order to achieve the result(efficiency)if we can achieve more output with less effort,that means productivity inc

6、reasesOEE|OLE Symposium-hhyeo-122007-01Effectiveness is determined by comparing what a process can produce with what they actually producedeffectiveness does not tell anything about the amount ofresources that have to be committed to obtain that output.if we are successful in manufacturing more good

7、 product in the same time period,effectiveness will increase.an equipment can efficiently cycle at the right speedand run all day,but how effective it is if only scrap is being produced?Effectiveness=do the right thingProductivity DefinitionOEE|OLE Symposium-hhyeo-122007-01Efficiency is determined b

8、y the amount of resources,i.e.time,energy,labor,etc that are necessary to obtain certainresults during certain periodif we are able to meet our daily production rate with less time and fewer operators,we have operated moreefficiently Efficiency=do the thing rightProductivity DefinitionOEE|OLE Sympos

9、ium-hhyeo-122007-01PCA and DF/MA products have different sets of resources used,the“Productivity”shall be measured separately to provide the right indication and area of focus PCA products,SMT equipment is the most critical installation and is having the highest proportion of the manufacturing cost;

10、we should measure“Overall Equipment Effectiveness”to ensure this heaviest investment is do the right thingDF/MA products,is normally labor intensive and labor cost makes up the bulk of the manufacturing cost;we should measure“Overall Labor Efficiency”to ensure our labor is being deployed to do the t

11、hing right as per the set standard Productivity ProposalOEE|OLE Symposium-hhyeo-122007-01OEE=Overall Equipment Effectivenessan indicator of how effectively a process/equipment is producing good quality products within the time it is planned to run and with the expected performancea tool used to anal

12、yze the process/equipment performance,accounting for losses due to Availability,Performanceand QualityOEEOEE|OLE Symposium-hhyeo-122007-01Objectives:measure and indicate the overall effectiveness of process/equipmentmonitor from both capacity(availability)and capability(performance&quality)point of

13、viewsustain and continuously drive the improvement of all aspects of process/equipment effectivenessmaximize the up time,deliver the quality output with the expected standard performance OEE OEE|OLE Symposium-hhyeo-122007-01OEE=Availability x Performance x Quality Availability Rate how much time the

14、 line actually runsversus the available timekey loss=downtimePerformance Rate how fast the machine actually runs versus the standard speedkey loss=placement speedQuality Rate how many good quality products were produced the first time key loss=defective productsOEE OEE|OLE Symposium-hhyeo-122007-01C

15、oncept Example:-a machine is capable of producing 800 units over 8 hours shift -with 1/2 hour lunch break,1 hour breakdown and 1/2 hour changeover,Availability=75%,max output=600-machine has to be slow down by 30%due to machine condition and new operator on board Performance=70%,actual output=420-FP

16、Y was bad due to maintenance and new operator Quality=80%,good output=336OEE=75%x 70%x 80%=42%OEE 800600420336OEE|OLE Symposium-hhyeo-122007-01OEE OEE=Availability x Performance x QualityAvailability rate=B/APerformance rate=D/CQuality rate=F/EOEE|OLE Symposium-hhyeo-122007-01World Class StandardAva

17、ilability=90%Performance=95%Quality=99%OEE=85%OEEOEE|OLE Symposium-hhyeo-122007-01OEE measures the overall equipment effectiveness,Our OEE measurement will focus on SMT onlyFrom screen printing process all the way to BSI/TSIAvailability Rate is the entire SMT line,from screen printing to BSI/TSIPerf

18、ormance Rate is the total machine placement rate from every single P&P machine in the lineQuality Rate is the FPYManual insertion,wave soldering,ICT,FVT,backend process,FNI,packaging,etc will not be included in the equation OEEOEE|OLE Symposium-hhyeo-122007-01OEE1.Availability Rate Actual Operating

19、Time-Availability Rate=Total Available Time-total available time per shift=8 hours-total available time per week=7 days x 24 hours=168 hours-actual operating time per shift=8 hours all downtime-denominator is a fixed constant,8 hrs(shift)or 168 hrs(week)-downtime can be retrieved from manufacturing

20、downtime record,and shall include all the planned/unplanned,internal/external,manufacturing,process,test,changeover,facilities,IT,machine breakdown,materials shortage,etc OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate Total Actual#of Placement-Performance Rate=Total Available#of Placement-to

21、tal available#of placement is the sum of available#of placement of each individual pick and place machine,both chip and IC placers,from the entire SMT line-IPC9850 Placement Standard is used as the standard to compute the total available#of placement -the total available#of placement varies from lin

22、e to line depends upon the actual line configuration-the IPC9850 Placement Standard was provided by the Director of ME as a proven achievable standard by using the IPC9850 test kit OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate-to obtain the total available#of placement per shift(the denomin

23、ator),simply multiply the total available#ofplacement to actual machine operating timeper shift-total actual#of placement(the numerator)can be obtained by sum of actual output of each individual product multiply by total#of SMT components of each correspondent product-the Performance Rate Per Shift

24、is then the numerator divides by the denominator OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate-IPC9850 Placement Standard for all the P&P machines used within Jabil attachment of IPC9850 matrix from Tom C.OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate-Example:-SMT configuration(NXT

25、Platform):-MPM M3-H12S M3-H12S M6-H01-XPM2-the total available#of placement per hour shall be:=11,213 CPH x 2+2,382 CPH x 1=24,808 CPH-this 24,808 CPH is the IPC9850 Standard Total Available#of Placement per hour-If the actual machine operating time was 6.8 hours per shift-The total available#of pla

26、cement per shift=6.8 hrs/shift x 24,808 CPH=168,694 CPS OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate-continued Example:-three products were running during this shift-ModelActual Output#of SMT components A 100426 B 100350 C 100297-total actual#of placement=(100 x 426)+(100 x 350)+(100 x 297

27、)=107,300OEE|OLE Symposium-hhyeo-122007-01OEE2.Performance Rate-continued Example:107,300-Performance Rate=168,694=63.6%OEE|OLE Symposium-hhyeo-122007-01OEE3.Quality Rate Standard-use the FPY data-this data can be obtained from the MES reportOEE|OLE Symposium-hhyeo-122007-01OEEOEE Templatea simple O

28、EE Template was developed to facilitate the current manual tracking process until a automation solution is reachedattachment of templateOEE|OLE Symposium-hhyeo-122007-01Improving the OEE-identify the key losses-calculate OEE-understand the root cause of all losses-team based problem solving techniqu

29、es to tackle the losses-focus on maximize machine operating time by eliminating downtimemaximize machine placement rate and process yield-OEEOEE|OLE Symposium-hhyeo-122007-01OLE Overall Labor EfficiencyObjectives:Measure the overall efficiency in the deployment ofdirect laborDeliver the targeted qua

30、lity output with the set number of direct labor at the pre-determined timeProvide an indicator to measure our labor efficiency and drive for continual improvementOLE OEE|OLE Symposium-hhyeo-122007-01OLE Overall Labor EfficiencyScope of measurement:PCBA backend lineMechanical assembly lineBox build l

31、ine DF lineOr any assembly line which is labor intensiveOLE OEE|OLE Symposium-hhyeo-122007-01OLE Formula:(total unit produced x standard man hour)(Total#of DL used x total paid hours)Total unit produced=actual production output Standard Man Hour=time required to perform the entire manufacturing proc

32、esses in order to produce one complete unit of final product,unit shall be in“HOURS”Total#of DL used=actual number of Direct Labor being deployed to perform the manufacturing processes to obtain the desired outputTotal paid hours=the actual hours being captured for wages computation OLE OEE|OLE Symp

33、osium-hhyeo-122007-01OLE Formula Notes:MOST(Maynard Operation Sequence Technique)shall be used to establish the standard man hourIf actual time study found that the actual standard man hour is lower than that of the MOST standard,please use the actual standard man hour as the new standardThe total#o

34、f DL used does include the supporting DL like line leaders,floaters,materials handlers,rework/debug operators and OBA.The DL here refer to the assembly,test,final inspection and packing operators,those who add direct value to the productsTotal paid hours shall be 8 hours per shift,unless we discount

35、ed the meal hours from the salary computation OLE OEE|OLE Symposium-hhyeo-122007-01OLE Formula Notes:If there are more than one product or model being produced during a shift,please sum up the actual output of each model x standard man hour of each model accordinglyOLE OEE|OLE Symposium-hhyeo-122007

36、-01OLE Example:With std man hour being constant,the actual out,#of DL used and production hours incurred will affect the final OLEOEE|OLE Symposium-hhyeo-122007-01OLEOLE Tracking TemplateOEE|OLE Symposium-hhyeo-122007-01OLEWhat can we do to improve the labor efficiency?execute per the established st

37、andardtraining,training,trainingeffective work method designergonomically workstation designlogical and sensible process and materials flowjigs/fixture/furniture aidperiodical time and motion study and reviewcontinual process improvement OEE|OLE Symposium-hhyeo-122007-01Roles&ResponsibilitiesOwnersh

38、ipManufacturing is the overall owner of these two indicatorsMFG shall be responsible for the tracking and reporting of these indicatorsThese indicators shall be recorded every shift and reported on the manufacturing whiteboardMFG shall take every effort to ensure the integrity and reliability of the

39、 data during this manual tracking periodMFG shall take the lead to work with all other functions(ME,IE,TE,QE,Materials,etc)to improve these indicatorsThese OEE and OLE indicator will be replacing the current Productivity when every site is ready with the tracking dataOEE|OLE Symposium-hhyeo-122007-0

40、1Roles&ResponsibilitiesOwnershipWorkcell Industrial Engineer(IE)and/or Manufacturing Engineer(ME)are responsible for providing the standard man hour of each and every product/model to MFG to compute the OLEWorkcell IE and/or ME shall update the standard man hour accordingly shall theres a change of

41、the standardThe Director of ME is responsible to provide the up to date IPC9850 Standard for all the P&P machines Workcell ME is responsible to provide the#of SMT components for each individual product to MFG to compute the Performance Rate until such data can be obtained from CamXOEE|OLE Symposium-

42、hhyeo-122007-01Reporting Format&Goal SettingBoth OEE and OLE shall be recorded and computed for every shift,reported in weekly basic and being reviewed in the weekly DBW meetingOEE shall be computed for each individual SMT line and sum up for each workcell,and then for plant wide number Workcell shall not to be discouraged by the number but make use of the indicators to drive continual improvementOEE|OLE Symposium-hhyeo-122007-01OEE|OLE Symposium-hhyeo-122007-01