Equipment loss refers to the downtime and inefficiencies that prevent machinery from operating at its full potential.
Whether it’s due to breakdowns, setup time, or minor stops, these losses directly impact the OEE score.
By identifying and addressing these issues, we can significantly boost operational performance.
Types of Equipment Loss in Manufacturing
Breakdown Loss
Breakdown loss involves unplanned downtime due to equipment failure.
This affects the Availability factor of OEE.
Setup and Adjustment Loss
Setup and adjustment loss occurs during equipment preparation for a new production run.
This impacts the Performance factor of OEE.
Measuring Equipment Loss
Precise measurement of equipment loss helps pinpoint issues impacting OEE.
Without accurate data, identifying the root causes of downtime, performance dips, and quality issues becomes challenging.
For instance, if breakdown losses are frequently miscalculated, maintenance schedules may not align with actual needs, leading to increased unplanned downtime.
Detailed data ensures that corrective actions target the right problems, thus optimising equipment availability, performance, and quality.
Tools and Techniques for Measurement
Various tools and techniques exist to measure equipment loss effectively.
Automated data collection systems, such as machine sensors and IoT devices, provide real-time insights into equipment performance.
For example, sensors can track machine vibrations to predict breakdowns before they occur.
CMMS (Computerised Maintenance Management Systems) helps schedule and record maintenance activities, ensuring timely interventions.
OEE tracking software can aggregate data on availability, performance, and quality, offering a comprehensive view of equipment efficiency. This software often includes analytical tools to break down loss categories, such as minor stops and speed losses, enabling targeted improvements.
Strategies to Reduce Equipment Loss
Preventive Maintenance
Regular preventive maintenance keeps equipment in optimal condition, reducing the likelihood of unexpected breakdowns.
Scheduling routine inspections helps identify worn or damaged parts early, thus avoiding major disruptions.
Utilising predictive maintenance tools, like vibration analysis and infrared thermography, can further enhance equipment reliability.
Incorporating Computerised Maintenance Management Systems (CMMS) ensures timely execution of maintenance tasks and systematically tracks equipment performance.
Lean Manufacturing Practices
- Implementing lean manufacturing practices targets waste reduction and improves efficiency.
- Applying methodologies like the 5S system ensures workplace organisation, which in turn minimises equipment loss.
- Value Stream Mapping (VSM) identifies inefficiencies in the production process, allowing for targeted improvements.
- Adopting Total Productive Maintenance (TPM) engages operators in daily maintenance tasks, fostering a proactive maintenance culture.
- Kanban systems streamline production flow, thus reducing equipment idle time and enhancing overall performance.
