1. 1. The Six Big Losses of OEE www.optimumfx.com
2. 2. What is Six Loss? It would feel odd to drive a car without a dashboard 6 loss Analysis is like the dashboard, providing useful information for making decisions at different times in your journey. Example: When there is an indication that you are low on fuel you will fill it up When the Revs are too high you will change gear
3. 3. Why use Six Loss? Six Loss allows you to accurately pinpoint the area of focus that will impact on the performance of the equipments output. To reduce each loss there is an improvement tool. All the Six Loss is doing is breaking down the equipments overall loss into six clear categories, to which, you can apply certain techniques to improve. It is what you do with this information makes the difference. Speed of Execution and intervention followed by monitoring is critical. Combine Six Loss data with using the right tools on the biggest loss and accelerate the speed of execution - This WILL improve the performance of your equipment. Many manufacturing plants spend a lot of time in measuring and recording data and dont use most of it. Sometimes less is more!!! This is a key part of your Manufacturing Strategy
4. 4. Set Up/Planned downtime Losses Planned Downtime This is the period of time between the last piece from one product run and the first piece of the next product run. That is: All time for flavour changes, CIPs , hygienes etc. that are necessary to fulfill the production plan. The way we can reduce the impact on output is to get smarter in the operation to reduce the time taken. Calculation to work out impact is: - Planned Downtime/(Paid time-NRFP)
5. 5. Breakdown Losses Breakdowns This is the amount of time lost at the bottleneck machine due to large stops (typically > 5mins) on any machine. This may be electrical or mechanical and is assumed to be a stoppage where a component has failed and has been repaired or replaced. Calculation to work out impact is: - Stoppage to critical machine/(Paid time-NRFP)
6. 6. Minor Stops Minor Stops This is the amount of time lost at the bottleneck machine due to small stops (typically < 5mins ) on any machine with an assumption that these events would not normally be a component failure, it is more likely to be an adjustment or a jam up, etc.
7. 7. Speed Loss Speed loss This is the amount of time lost between the start and finish of a production run due to the bottleneck machine / Critical machine running below its rated speed. The formula for calculating this loss is: -
8. 8. Quality loss on start up Quality loss on start up This is the run up period after a changeover when settings need final adjustments to bring the product into exact specification to enable running. That is: Alterations to saturation pressures or brix adjustments etc. that ensure product specification. As this is an exceptionally hard area to calculate automatically it is split out into the other areas of loss.
9. 9. Quality loss during running Quality Loss in Process This is a loss of product during a production run where quality does not meet specification. All non re-workable rejects. That is: A low filled bottle, a poorly fitted cap etc.
10. 10. The Six Loss Tool Kit Six loss category OEE measure Reason for Loss Countermeasures Planned downtime or external unplanned event Availability Changeovers Planned maintenance Material shortages Labour shortages Planned Downtime Management 5S Workplace Organisation ABC Planning Breakdowns Availability Equipment failure Major component failure Unplanned maintenance Kaizen Blitz ProACT Root cause analysis Asset Care Minor stops Performance Fallen product Obstruction Blockages Misalignment Cleaning 5S Workplace Organisation Adjustments Line Minor stop audits Speed loss Performance Running lower than rated speed Untrained operator not able to run at nominal speed Line Balance Optimisation Adjustments Production rejects Quality Product out of specification Damaged product scrap Six Sigma Error proofing Root Cause Analysis Rejects on start up Quality Product out of specification at start of run Scrap created before nominal running after changeover Damaged product after planned maintenance activity Planned Downtime Management 5S Workplace Organisation Standard Operating Procedures Precision settings
11. 11. Calculating Six Loss Six Loss Category Calculation Total Production Time = Total Time - NRFP Planned downtime or external unplanned event Planned Downtime Total Production Time Breakdowns (>5mins) Time Loss at Critical Machine due to stoppages >5mins Total Production Time Minor stops (