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Performance Monitoring

The document discusses key performance metrics for equipment: availability, utility, reliability, and productivity. It provides formulas and examples to calculate each. Availability measures downtime as a percentage. Utility measures actual usage hours. Reliability measures mean time between failures. Productivity compares actual to planned or targeted output. The document recommends tracking overall equipment effectiveness (OEE) which considers availability, performance efficiency, and quality to assess total machine performance.

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dcsekhar
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63 views11 pages

Performance Monitoring

The document discusses key performance metrics for equipment: availability, utility, reliability, and productivity. It provides formulas and examples to calculate each. Availability measures downtime as a percentage. Utility measures actual usage hours. Reliability measures mean time between failures. Productivity compares actual to planned or targeted output. The document recommends tracking overall equipment effectiveness (OEE) which considers availability, performance efficiency, and quality to assess total machine performance.

Uploaded by

dcsekhar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Equipment Performance

Monitoring

Availability Utility
EE
O

TO
A
Productivit
y Reliability
Availability

Availability is the measure of downtime of equipment, i.e how much


the equipment is available for use.

Total Hours in a month –


Breakdown Hours
Availability % = x100
Total Hours in a month

During Nov’09 ,a wheel loader at Bhushan Steel Job was under


breakdown for , 3 days i.e. 72 hrs.
What is the availability % ?
(24 hrs x 30 days) – 72 hrs 720-72
Availability = = x 100 = 90% (24 hrs x
30 days) 720
Utility

Utility is the measure of actual usage of equipment. It is normally


measured on a 12 hrs clock.

Hours Worked
Utility % = x100
26 days x 12 hrs a day

During June’09 ,one 500 kva Power Generator has run for 250 hrs.
What is the Utility % ?

250 hrs 250


Utility % = = x 100 = 80% (24 hrs x 30
days) 312
Reliability

Reliability is the probability that an equipment performs its intended


function for a stated period of time, under specified operating
conditions.It is measured as MTBF.

Hours Run
Reliability(Hrs) = Mean Time Between Failures =
No.of Breakdowns

During Jan’09 ,Batching plant has run for 250 hrs.It was breakdown
for 10 times during this month.
What is the Reliability ?
250
Reliability = =25 hrs 10
Availability Vs Reliability
Shift Hour/Planned Hours = 100 Hrs
Hours Run= 95 Hrs
Break down Detail
Day-1 = 30 min+15 min =45min
Day-3 = 45 min +15 min = 1 hr
Day-4 = 15 min
Availability Reliability Day-6 = 15 Min + 45 min =1 hr

Shift Hours = Hours Run= 95 Day-7 = 30 min


100 hrs Day-8 = 30 min
Break down =5 Stoppages= 10 Day-10 = 1 Hr
hrs
Total Break down = 5 Hrs
Available MTBF = 95/10 ~
Hours/Shift Hours 10 Availability Vs Reliability- Avly.
= 95/100=95% Failure in every is measure of duration of downtime
where as Reliability is the measure
available 10 hrs !!! of frequency of downtime.
Asset Turn Over
Month Sales(Cr) AV(Cr)
1 100 100
2 50 105
ATO = Sales
3 75 110
Avg.AV
4 25 140
5 150 140
6 300 140
7 200 160
8 25 160 ATO = 1500/150 =10
9 150 165
10 100 180
11 50 195
12 275 200
1500 Cr 150Cr
Productivity

(A) Output Plant


Time taken Productivit
In other words, it is “Rate of Production” y
e.g. 25 m3/hr in a CP30 batching plant

(B) Actual Production Plant


Target Production Productivit
This is used in “Process Plants” y
e.g. 6000 m3 concrete planned for Dec’09-
Actual achieved= 4000 m3
Plant Productivity = 66%
Way ahead….
Overall Equipment Effectiveness(OEE)
OEE
• It is a severe measure of total machine performance, showing the
overall picture of where time is lost
• It categorizes time losses for the purpose of improvement
Formula

OEE = A x PE x Q
A - Availability of the machine

PE - Performance Efficiency. It is given by RE X SE.


Rate efficiency (RE) : Actual average cycle time is slower than design cycle
time because of jams, etc. Output is reduced because of jams
Speed efficiency (SE) : Actual cycle time is slower than design cycle time
machine output is reduced because it is running at reduced speed.

Q - Refers to quality rate. Which is percentage of good parts out of total


produced sometimes called “yield”.
6 BIG LOSS OF OEE?

“Traditional efficiency measure captures


only part of time losses”

Reduce
Reduce
Changeover
Changeover Breakdown
Breakdown d
d
Speed
Speed

Micro
Micro Quality
Quality
Spoilage
Spoilage
Stops
Stops Defects
Defects

10

Other time losses captured in OEE


OEE Pilot study

Microsoft Office
PowerPoint Presentation

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