A common complaint we hear from CMMS system users looking a purchasing our product is that their old CMMS contained a lot of data however it was difficult or impossible to use the data due to poor reporting and analysis features. Our CMMS system offers simple ways to always analyze and report on ALL data in the system. A useful example of this is how MaintSmart leverages downtime data into OEE reporting.
OEE (overall equipment effectiveness) is derived from the downtime data providing a valuable KPI. Actually the OEE roll-up KPI is composed of three (3) important KPI values:
- Equipment performance
- Product quality
Availability is the operating time/planned production time. This takes into account losses due to equipment failures. This CMMS system has a dedicated downtime (equipment failure) tracking system that provides the necessary data for the overall equipment effectiveness component. Another often overlooked source of availability loss is changeover time. This is time that could otherwise be used for production and should be accounted for.
Quality is defined as Good Pieces Produced/All Pieces Produced. Normally you may not consider quality to be a maintenance management issue but good running equipment produces better quality product generally speaking. Therefore quality is included in the overall equipment effectiveness KPI. More often the quality losses are a result of start-up losses, changeover losses and possibly improper speed settings by equipment operators. These should all be considered but may be beyond the control of the maintenance manager.
Equipment manufacturers define a Ideal Equipment Run Rate (Ideal Cycle Time). An example for a bread divider (cuts dough balls to form a bread loaf) might be 200 loaves/minute. This is the design cycle time. Whether this rate is accomplished could be dependent upon several factors. However a poorly running equipment item typically results in a poorer performance overall equipment effectiveness KPI.
Where to Implement OEE?
Collecting CMMS program data for the purposes of overall equipment effectiveness analysis should begin with equipment bottlenecks on the production line (sometimes referred to as the constraint). The line or process will be limited by this bottleneck so there is no point is monitoring all the equipment on a line. If the bottleneck is resolved then find the next bottleneck and monitor it.
How to Collect OEE Data (Downtime)
Good data must be used for OEE and it's component parts to be of any use. CMMS system data from the downtime data table is an integral part of the overall equipment effectiveness data collection process. Downtime data may be entered manually or imported from the downtime data table into the overall equipment effectiveness analysis function. Obtaining the Quality parameter needed for OEE may seem fairly straight forward however care should be taken not to include re-worked product that was initially rejected. The Performance KPI requires an Ideal Run Rate and the Planned Production Time. Planned production time is the scheduled production run time less breaks of any type other than unplanned downtime.
How Do We Rate with OEE?
The typical OEE value for manufacturing is in the 60% range. World class OEE values are above 80%. This indicates that many of these typical manufacturing plants could improve dramatically by implementing OEE, identifying bottlenecks and correcting these issues. With this CMMS system all the tools needed to correct and improve are available in the base module. These tools include extensive down time analysis, a powerful query-builder, multiple reporting methods and military standard reliability analysis.