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Downtime

Manufacturing downtime refers to any period when a facility's output is stopped. Downtime includes both planned maintenance stoppages as well as unplanned issues like equipment failures. Common causes of downtime are maintenance, human errors, software or hardware malfunctions, and environmental events. Tracking downtime details like timestamps, descriptions, and root causes helps determine metrics like mean time to repair and mean time between failures, allowing companies to reduce costs and improve processes over time.

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89 views7 pages

Downtime

Manufacturing downtime refers to any period when a facility's output is stopped. Downtime includes both planned maintenance stoppages as well as unplanned issues like equipment failures. Common causes of downtime are maintenance, human errors, software or hardware malfunctions, and environmental events. Tracking downtime details like timestamps, descriptions, and root causes helps determine metrics like mean time to repair and mean time between failures, allowing companies to reduce costs and improve processes over time.

Uploaded by

Jigar Desai
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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Downtime

• Manufacturing downtime is any period of time during which facility output is


stopped.
• Manufacturing downtime includes planned downtime for scheduled asset
maintenance, as well as unplanned downtime due to equipment failure and other
events.
• Downtime has many causes, including shutdowns for
• Maintenance.
• Human errors.
• Software or hardware malfunctions.
• Environmental disasters such as power outages, fires, flooding.
• Downtime records would be associated with Time stamp, Description, Code,
Reasons(upto Level 4 Machine, Sub Machine, Rootcause, Stop reason),
Categories.
• Downtime helps to find MTTR and MTBF.
• Reduce maintenance cost, understand the trend.
Bottles Cap Supplier

Bottle Sorter Filler Capper Sealer Labeler

Palletizer Packer
OEE Formula

Availability
Availability = Run Time / Planned Production Time
Run Time = Planned Production Time − Stop Time

Performance
Performance = (Ideal Cycle Time × Total Count) / Run Time

Quality
Quality = Good Count / Total Count
Planned Production Time
OEE CALCULATION EXAMPLE OEE calculation begins with Planned Production Time.

Exclude any Shift Time where there is no running production


ITEM DATA (typically Breaks).
Shift Length 8 hours (480
Formula: Shift Length − Breaks
minutes)
Example: 480 minutes − 60 minutes = 420 minutes
Breaks (2) 15 minute and
(1) 30 minute
Run Time
Downtime 47 minutes calculate the amount of time that production was actually
running (was not stopped).
Ideal Cycle Time 1.0 seconds
Stop Time should include both Unplanned Stops (e.g.,
Total Count 19,271 widgets Breakdowns) or Planned Stops (e.g., Changeovers). Both
provide opportunities for improvement.
Reject Count 423 widgets
Formula: Planned Production Time − Stop Time
Example: 420 minutes − 47 minutes = 373 minutes

Good Count
Formula: Total Count − Reject Count
Example: 19,271 widgets − 423 widgets = 18,848 widgets
Availability
It accounts for when the process is not running (both Unplanned Stops and Planned Stops).

Formula: Run Time / Planned Production Time


Example: 373 minutes / 420 minutes = 0.8881 (88.81%)

Performance
It accounts for when the process is running slower than its theoretical top speed (both Small Stops and Slow
Cycles).
Formula: (Ideal Cycle Time × Total Count) / Run Time

Example: (1.0 seconds × 19,271 widgets) / (373 minutes × 60 seconds) = 0.8611 (86.11%)

Quality
It accounts for manufactured parts that do not meet quality standards.

Formula: Good Count / Total Count


Example: 18,848 widgets / 19,271 widgets = 0.9780 (97.80%)

OEE
Finally, OEE is calculated by multiplying the three OEE factors.

Formula: Availability × Performance × Quality


Example: 0.8881 × 0.8611 × 0.9780 = 0.7479 (74.79%)

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