x Continuous Improvement in Daily Work

Q: How to make Continuous Improvement Activities a part of daily work?

This question regularly is being asked when companies join a Lean– or TPM journey.

Arno Koch •  Continuous Improvement indeed should not be a project, an incidental activity or a staff-member job. So how to engage everybody in the factory to get involved in improvement activities on a daily basis?

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x Calculate OEE on an hourly basis

Q: Suppose I want to calculate OEE continuously during the running shift, in order to present the team an ongoing status, how should I calculate this, specially when the machine is not running? Does the OEE drop to zero?

What if the Availability has been 50% for last hour but the actual production has been zero? What do you do with the Performance number? Should it be equal to zero?

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x Calculate OEE per hour

Q: Suppose I want to calculate OEE per hour, continuously during the running shift, in order to present the team an ongoing status, how should I calculate this, specially when the machine is not running? Does the OEE drop to zero?

What if the Availability has been 50% for last hour but the actual production has been zero? What do you do with the Performance number? Should it be equal to zero?

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x Spillage

Q: Should spillage be considered in OEE calculation?

Let’s say I’m producing 90 pieces instead of an expected 100. Then my OEE should be 90/100 = 90%. But now consider the conveyor is faulty because of which 10 pieces got spilled (without stopping the line). These 10 pieces spillage are waste as those can’t be use as finished goods. So 90-10 = 80 is my actual output now. In this case, my OEE should be 80/100 = 80% right?

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x Quality Rate can not be determined immediately

Q:  Sometimes our process is being interrupted; i.e. the oven is stopped at a different moment than planned. At that moment it is not clear whether the product will be OK or not. We will block the product and take samples to determine the quality. This could take a couple of days. Wen everything is OK the product is released, otherwise it is being scrapped. This would have a retrospective effect on the OEE I guess? A correct quality rate -and thus OEE- for the day is no longer possible in this way. What number should I now use?

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x OEE in long-run milling process

Q: We are tool & die maker for  the automotive industry. Overall each die will take 20 to 35 days (based on size) to complete. Depending on the shape (contour) of the die, the process is done manually or auto mode. The mode depend on our CAD/CAM capability to do the programming.

How do we calculate OEE in our milling process?

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