OEE tracking system

Real story: OEE improvement resulted in revenue increase of Rs. 32,00,000 per month.

OEE tracking system improved OEE by 23%

OEE increased by 23 % in just 5 months, using  the OEE tracking system that is part of Leanworx.
By getting accurate and timely data on downtime and rejections.
Revenue increase: Rs. 44,000 per machine per month, Rs. 32,00,000 total per month.

OEE monitoring system benefits
About the Leanworx user

Automobile parts manufacturer with 72 machines, using Leanworx for OEE tracking and improvement. Machines are CNC lathes, VMCs, HMCs, sand moulding machines, core shooters, fettling machines. Average machine hour rate Rs. 350.

Before Leanworx

The OEE varied from 32 % to 65 %, depending on the type of machine. CNC machines were the lowest.

After installing Leanworx

After the firm started using Leanworx, OEE improved by up to 23 % on CNC machines, 15 % on foundry machines. Result: higher profits because of higher production quantities with the same number of machines, lower cost of production per part, lower rejections, reduced raw material cost.

How did the transformation happen ?

Leanworx OEE tracking system provided the management a clear picture of OEE, downtime durations and reasons, and rejection quantities and reasons. On CNC machines there was drastic reduction in late starting and early stopping in the first month itself.

Leanworx OEE trend reports highlighted a number of problems. In the first couple of days it was found that the last 2 to 3 hours in the night shift showed zero production. This too resolved itself. Waiting for raw material was a common cause of downtime that as identified, focused upon and reduced. Rejections in a few CNC machines and in the mould making were high, and were reduced. Frequent breakdowns in some old CNC machines and in the air supply to core shooters were identified as key causes of reduction in availability.

Leanworx sent automatic alerts to personnel at various levels on their mobile phones – alerts for breakdowns, big downtimes, high rejections, etc. Immediate action was taken on such alerts.

OEE tracking system - features in Leanworx

OEE is a single number that measures how well you are using your machines, your capacity utilization. It has a direct impact on your profits. In a single number, it measures:
1. How much time a machine is running out of the total available time. Availability.
2. How efficiently it is producing in the time that it is running. Performance.
3. How good the quality of the parts are. Quality.

The OEE is actually a direct measure of your capacity utilization. If you have 10 machines and 50% OEE, you are using 50 % capacity, or the equivalent of 5 machines. If you increase the OEE to 70%, you have added 20% capacity, or the equivalent of 2 machines.

Leanworx OEE tracking system has features that help you track and improve all the 3 ingredients of OEE: Availability, Performance and Quality.

There are a variety of OEE tracking reports:
– Dashboards showing the current shift OEE, production, downtime.
– Andon board on large LED displays on the shop floor showing the shift OEE, production, downtime.
– OEE reports shift-wise, day-wise, week-wise, etc., with Availability, Performance and Quality, and the breakup of the calculation for arriving at the values.
– Long term OEE tracking trends month-wise, quarter-wise etc.
– Comparison of OEE between multiple machines and collection of machines – cell, shop, plant.
– CEO reports showing a bird’s eye view of OEE in multiple plants.

An OEE tracking system is of course dependent on improvement of the 3 ingredients of OEE – Availability, Performance, Quality. Leanworx has a lot of features for improving these.

OEE tracking - features for Availability

Availability is the ratio of the time that the machine was available to work, to the total time available. Availability is affected by downtimes. Leanworx has highly efficient machine downtime monitoring. Machine downtime durations are tracked directly from machine signals, automatically, 24/7, without any human intervention. Reasons for downtime automatic if machine signals are available, or via operator devices that are part of the downtime monitoring system.

There are extensive downtime reports:
– Report of each machine downtime – when it started and ended, its duration and reason.
– Downtime analysis reports. Pareto, pie charts and tabular reports, to enable you to focus on the top causes of downtime and reduce them.
– Report of downtimes at shift change, to reduce late starting at the start of shifts and early stoppage at the ends of shifts.
– Trend reports of machine downtime to show you how your actions are yielding results – day-wise, week-wise, month-wise, quarter-wise.
Alerts on mobile phone and email for machine downtimes that require immediate action:
– Alert to shop supervisors and managers on abnormal downtime beyond a pre-set time period that you can specify.
– Alert to maintenance personnel on machine breakdown.
– Alert on downtime due to a specfic reason.
– Escalation alert escalation to higher level personnel if downtimes exceed pre-set levels.

Machine downtime reduction becomes rapid and systematic with these features. Use alerts to respond to crises situations like machine breakdowns. View machine downtime analyses regularly, identify key causes of machine downtime and reduce them systematically. You can see reports and alerts any from anywhere in the world, any time of day, on any device – desk top, laptop, tab, mobile phone.

OEE tracking - features for Performance

Performance is the ratio of the quantity produced to the quantity that could have been produced. Production quantity is tracked automatically from the machine, and available as a variety of reports. There are alerts for crisis management.
– Reports of hourly production and hourly planned quantity.
– Shift-wise and day-wise production reports.
– Details of individual cycles – start and end time of cycle, cycle time, downtime between cycles for part unload-load.
– Batch-wise production showing work order number, start and end date and time of batch, quantity planned, quantity produced.
– Trend of production quantity.
– Alert on mobile phone or email on production target shortfall, to production supervisors and managers.
– Andon boards on large LED screen on shop floor showing the current production, target, downtime, OEE, etc.

OEE tracking - features for Quality

Quality of the ratio of good parts produced to total parts produced. It is affected by part rejections. Rejection quantities and reasons are captured from signals from the machine or inspection devices, or from operator input systems. A variety of reports and alerts help you focus on the big causes of rejections and fix them – machine process capability, process improvements, raw material problems, operator skill levels.
Quality reports and alerts:
– Rejection details showing each instance of a rejection with date and time,operator, reason.
– Rejection reasons analysis – Pareto, pie charts, tabular reports.
– Rejection trends over days, weeks, months, to show you if your actions are paying off.
– Alert on high rejection percentage.
– Alert on rejection due to a particular reason.

Here are some of the reports from the OEE tracking system, that the firm used to achieve the transformation.

Firm and machine names have been changed to protect the identity of the firm.

OEE monitoring with machine monitoring system on Industry 4.0
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