Seven Equipment Productivity Thieves
by Tom McBride,
Partners for Creative Solutions, Inc.
Our previous article entitled “Need More from Your
Equipment?” described how to use the
Overall Equipment Effectiveness (OEE)
metric to compare the performance of your equipment to world-class.
This article continues by discussing seven productivity thieves that
reduce throughput and OEE.
– The machine cannot run because material has not arrived (from vendor
or internal source), an operator is not available, or there is some other
management issue. Although
waiting is more of a managerial issue than an equipment loss, it negatively
– These disruptions come when you can least afford them, extending
schedules, requiring premium costs for repairs and overtime, and generally
causing chaos. Breakdowns can be
reduced with effective preventive and predictive maintenance systems, but
achieving zero breakdowns requires that operators be equal parties in caring
for the equipment.
and adjustments – There are proven ways to reduce set-up time, but
some organizations do not go far enough.
For example, a popular way to reduce die changeover time in a press
is to create accurate reference points, add quick release fasteners, etc. However,
trial runs and adjustments after the tooling has been changed are often 50%
of total changeover time and must be addressed to gain maximum benefit.
and minor stoppages – Although these stoppages may be short, they add
up over time. For example, a
machine shuts down for no apparent reason several times a day.
It only takes a couple of minutes to restart the machine, so the
condition is tolerated. Minor
stoppages can cost more in the long run than breakdowns, because nothing
forces you to fix the problem.
speed – Are machines being run at rates slower than the standard they
are capable of achieving?
defects and rework –Defects and rework reduce throughput, increase
production costs, and prompt firefighting.
Fortunately, effective countermeasures exist that involve both early
detection and prevention.
losses – This is typically the scrap generated during a stabilization
period at the beginning of a production run.
Reducing these losses requires a good understanding of the process
and ample creativity.
Sufficient data on equipment performance will enable you to
identify the major culprits. Typically
one or two are making a huge impact on OEE, and these can be attacked first.
Learn more about improving equipment effectiveness using Total Productive
Maintenance (TPM) at www.pcs-info.com/library.htm.