OEE PT. Santos Jaya Abadi Instant Coffee

Plant

Created By Anang

Raya Panjunan Km 3

1. Apa Kepanjangan Dari OEE ?2. Jelaskan Pengertian / Definisi Tentang

OEE ?3. Factor apa yang Mempengaruhi OEE ?4. Jelaskan Tentang AVAILABILITY ?5. Jelaskan Tentang PERFORMANCE ?6. Jelaskan Tentang QUALITY ?7. Jelaskan Tentang Downtime ?

Pre Test

Garis Besar :PengenaIan OEEOEE ManufacturingResep rahasia: I x F x AStudi kasus: OEE Improvement

The Power of OEE

1. PENGENALAN OEE

Created By Anang

OEE (Overall Equipment Effectiveness) adalah cara "best practice" untuk memonitor dan mengimprove effectiveness dari manufacturing processes (i.e. machines, manufacturing cells, assembly lines).

• OEE adalah metriks terpadu yang mengukur tingkat yang dihasilkan dari suatu proses

Definisi OEE

Masurement adalah dasar dari improvement"

Zero Losses Zero Breakdowns Zero Defects Zero Accidents

Continuous Improvement Berkesinambungan Berdasarkan Team Work Activity Tidak Tergantung Orang-2 Tertentu

World Class Manufacturing company

Tujuan OEE / Goals

Production Engineering / Maintenance Quality Control / Assurance Human Resources Development Management And all related parties who can contribute

Siapa Yang Akan Melakukan OEE ?

Body Mass Index Kategori

> 30 OBESITAS

25,0 - 29,9 OVERWEIGHT

18,5 - 24,9 NORMAL

< 18,5 UNDERWEIGHT

Measurement create Crisis

mass(kg)BMI =

(height(m))2

You can’t improve if you don’t control You can’t control if you don’t measure You can’t measure if you don’t check You can’t check if you don’t understand You can’t understand if you don’t learn You can’t learn if you don’t know You won’t know if you aren’t willing

You can’t improve if you aren’t willing

Major Losses

Losses Due To Machine

Breakdown

Losses Due To Set Up, Change Over

Losses Due To Deffect

Losses Due To Rework

Speed Loss Minor Stopage

“Berapa Resources Yang Terbuang”

Input : Machine Man

Power Material Energy

Knowing your Losses is very valuable!

Losses adalah pemakaian resource yang tidak dirasakan oleh end customer tapi hanya menambah biaya produk

Time Diagram

Manned time Unused

time

Change overtime

- No Order No Activity

- Idle time

- “Extra” cleaning, training, meetings

- Speeds less than nominal capacity

- Minor stops (< 15 minutes)

- Cleaning

- Trial

- Start-up / Shut down mesin

- Set-up and

equipment adjustment

- Breakdowns mechanical (> 15 minutes)

- All quality defects

including products on hold

Theoretical Prod. Time =

good product / nom.capacity

- Shift system

- Nights & Weekends

unmanned

- Holidays

Effi

cie

ncy

Pre

para

tion

Qu

ality

Perfo

rman

ce

Availa

bility

Good product orTheoretical

Production time

Reject &rework

Speed losses &

minor stopsProduction time

Planneddowntime

YearlyMaint.

Team

main

t.ra

tio.

NONAEffective working time

Lab

ou

r.P

lan

.Eff

.

- shut down / overhole

OP

I

OP

I NO

NA

Eff

ecti

vit

y

Externalstops

no electricity, no steam, no compressed air, no water

Total time

Actual production time

Breakdowntime

Operating time

Available production time

OEE COMPOSITION

Company OEE

Awal Untuk OEE Umum 30% - 50%

World Class OEE 85% - 95%

World Class OEE

OEE = Availability x Performance x Quality

OEE Formula

OEE

Availability

Performance Quality

Breakdown Losses Minor Stoppage Scrap/Rework

Setup & Adjustment Speed Losses Start Up

Six Big Losses

Created By Anang

2. OEE Manufacturing

OEE & Lean ManufacturingBusiness Result

Return Of Stageholder EquityOperating Margin, Cash Flow

Operating Excellence

Continous Improvement

OEE – Operational Stability5R Stadndart Work, Maintenant Management

PeopleLean

Processes

Six Big Losses

Model OEE OEE = Availability x Performance x Quality

Perusahaan ManufacturingRunning Time = 8 JamBeakdown Mesin = 60 menitSetup Adjustment = 30 menit

Availability = (Actual Running Time / Planed Running Time) x 100%

= (8 Jam – (60+30 Menit) / (8 Jam)) x 100%

= 81 %

Contoh : Availability Calculation

Avaiability Time = 8 Jam – 1,5 Jam = 6,5 JamTheoritical Speed = 120 Pcs / Jam Actual Output = 580 Pcs (Good+Reject)

Performance = (Actual Output/Theoritical OutPut) x 100%

= (580 Pcs/(120 Pcs/Jam x 6,5 Jam)) x 100%

= 74%

Contoh : Performance Calculation

Actual Output = 580 Pcs (Good+Reject)Good = 500 PcsReject/Rework = 80 Pcs

Quality = (Actual Good / Actual Output) x 100%

= (500 Pcs/580 Pcs) x 100%

= 86%

Contoh : Quality Calculation

Availability = 81%Performance = 74%Quality = 86%

OEE = Availability x Performance x Quality

= 81% x 745 x 86%

= 52%

Contoh : OEE Calculation

3. Latihan Menghitung OEE

Latihan Menghitung OEE

Diketahui :

Total Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Theoritical Speed =2.000 Botol/Jam Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol

Hitung : Availability, Performance, Quality dan OEE ?

Hitung OEE Manufacturing

Availability : (7 x 60) – (45 x 2) / (7 x 60) : 330 / 420 : 78,57 %

Performance : 6.300 / ((330/60) x 2.000): 6.300 / 11.000: 57,27 %

Quality : 5.900 / 6.300: 93,65 %

OEE : 78,57 % x 57,27 % x 93,65 % : 42,14 %

Jawaban Soal :1

Diketahui :

Running Time = 7 Jam Breakdown Mesin = 45 Menit Setup Adjustment = 45 Menit Cleaning Mesin = 20 Menit Theoritical Speed =2.000 Botol/Jam Idle menunggu Kemasan = 15 Menit Actual Output = 6.300 Botol (Good & Reject) Good Product = 5.900 Botol; Reject = 400 Botol Jumlah Yang Bisa di Rework = 200 Botol

Hitung : Availability, Performance, Quality dan OEE ?

Hitung OEE Manufacturing

How To Improve OEE

Information x Focus x Action

Improve OEE

Result = I x F x A Terlalu Banyak Data, Tetapi Tidak Banyak Informasi

Tidak ada Informasi Dapat Berarti Keputusan dibuat Berdasarkan Insting.

Ketiadaan Informasi menyebabkan tidak ada focus di perusahaan

Tidak ada Fokus utama untuk Improvment.effisiensi hanya menjadi sakah satu performance Indikator, tetapi belum menjadi sasaran satu perusahaan.

Tidak ada nya fokus menjadi penyebab tidak adanya alasan nyata untuk aksi.

Tidak ada aksi untuk mencapai sasaran bersama.

Semua menjalankan bisnis as ussual (seperti biasanya)

Accurate Data As Close to real time as you can get it Focusing On what caused you to be off track Review regularly and act !!!

Informasi Yang Tepat

Collect Data pada banyak mesin, masalah produkstivitas,Tidak ada waktu - terlalu sibuk

Data tidak akurat :Tidak merekan minor StopMembulatkan angkaBudget Time

Karena data idak akurat, maka data tidak dipakai, sehingga operator tidak mengisi dengan benar.

Hasilnya : Tidak ada improvement

Issue menggunakan manual data collection

Keuntungan Automated Data Collection

Manual System - Reaktif Automated System - Proaktif

Slow Reaktion Rapid Reaction

Historical Information Real Time

Snap Shot Audit Continous Visualization

Inaccurate data Accurate Data

Perceived Losses On Critical Machine Real Losses on Critical Machine

OEE Score Board (OEE DashBoard)

Terima kasih

1. Apa Kepanjangan Dari OEE ?2. Jelaskan Pengertian / Definisi Tentang

OEE ?3. Factor apa yang Mempengaruhi OEE ?4. Jelaskan Tentang AVAILABILITY ?5. Jelaskan Tentang PERFORMANCE ?6. Jelaskan Tentang QUALITY ?7. Jelaskan Tentang Downtime ?

Post Test