by Ross Kennedy, 6 December 2018
The Overall Equipment Effectiveness or OEE Loss Analysis Spreadsheet is a very powerful tool to assist in more fully understanding not only where all the equipment losses are originating from, but most importantly the impact they will have when correctly addressed. The spreadsheet consists of 8 interlinked sheets and uses a bottling line example to demonstrate how it should be used.
Sheet 1 is the Second-Level OEE Loss Analysis Sheet which captures the loss data collected from Daily Production Reports and Team Observations so as to develop the ‘as-is’ situation based on 3 weeks of production reporting and 3 Observations typically of 4-6 hour duration.
Sheet 2 is the Second-Level OEE Loss Summary Sheet which is used to interpret the initial OEE Loss Data using Pareto charts looking at the total loss by sections of the line as well as total loss by loss type.
Sheet 3 summarises the data collected in sheet 2 into a First-Level OEE Loss Analysis Sheet which can be used to present to the site Leadership Team and other people working in the area if required.
Sheet 4 is the Second Level OEE Improvement Visions Sheet which is used to develop an Ideal Vision (typically 3 years out) and a 12-month Vision with supporting reasons or assumptions for each loss category for approval of the Site Leadership Team. This allows a realistic target for OEE to be created recognising some of the reasons or assumptions could change in the future; such as extra products being introduced requiring more set-ups or changeovers each day or week.
Sheet 5 is the Second-Level OEE Improvement Gap High Level Opportunity Analysis Sheet which is used to identify whether a Production Area Based Team conducting Work Area Management / 5S or Operator Equipment Management / Autonomous Maintenance should address a loss or whether a Cross-functional Improvement Team is more suited.
Sheet 6 is the Second-Level OEE Improvement Targets Sheet which is used to identify where the Cross-functional Improvement Team doing the OEE analysis will target to achieve their mandate which is typically a 25% improvement in OEE.
Sheet 7 is the Production Area or Line Cost-Benefit Sheet to allow the improvement team doing the analysis to determine the cost and annualised benefit of each proposed improvement so as to simplify the justification process for the proposed improvements.
Sheet 8 is the First-Level OEE Improvement Summary Sheet which is used to summarise the analysis for the improvement team’s final presentation to the Site Leadership Team.
The OEE Loss Analysis Spreadsheet should be repeated each 12 months for the Production Area or Line in order to monitor OEE improvement progress / achievements and to set a new OEE improvement plan for the next 12 months.
If you would like to learn more about CTPM – The Centre for Australasian TPM & Lean, and our approach to OEE, contact myself Ross Kennedy at firstname.lastname@example.org or purchase my OEE book using this link.