Oee PDF
Oee PDF
Oee PDF
ABSTRACT Recent developments in engineering failures (MTBF) is more, it indicates machines are
optimization allow choosing the best input values thereby available for its desired performance. Attempt must be
enhancing the effectiveness of any equipment. Overall made to reduce mean time to repair (MTTR) and improve
Equipment Effectiveness (OEE) is a performance measure MTBF. It requires failure data analysis and root cause
which employs factors such as availability rate, analysis. The failure data collected will help us to
performance rate and quality rate to determine the calculate availability (A) of equipment.
efficiency of a manufacturing system. In this paper,
Overall Equipment Effectiveness (OEE) is optimized OEE = A * PR * QR
using Genetic Algorithm to achieve the best utilization of
the plant resources. The availability rate of the machine, MTBF = Total breakdown time / Number of occurrence
performance rate of the machine and quality rate of the MTTR = Total repair time / Number of occurrences
products are considered as parameters while maximizing
the Overall Equipment Effectiveness (OEE) of a Availability = MTBF / (MTBF + MTTR)
manufacturing system. It is found that the lagging in Performance Rate = (e * ts) / Actual operating time
performance rate contributes more than availability rate Quality Rate = (Output - Rejected) / Output
and quality rate that deficiency of effectiveness in the
system. It is concluded that maintaining the performance Nomenclature
rate above 95% will result in effective utilization of the
considered manufacturing system. A Availability
MTTR (Min.)
MTBF (Min.)
Total Repair
Genetic Algorithm is employed to optimize the Overall
Time (Min.)
Time (Min.)
occurrences
Availability
Breakdown
Number of
Machine
Process
Equipment Effectiveness (OEE) of a manufacturing
Total
system.
Literature review in the field of overall equipment
effectiveness shows that there is strong need of
performance measurement system. It indicates to reduce
Extruding
down time losses, speed losses for performance
E-01
0.85714285
120 20 4 30 5
improvement. 7
0.85411665
CB-02
90 7 2 45 3.5 0.9278
CU-03
140 6 3 47 2 0.9589
BM-01
Bead Making
0.844155844
150 15 4 38 3.8 0.9090
BM-02
Size of the tyre : 3.50inch X 10inch Quality Rate = (Output - Rejected) / Output
Weight of the tyre : 3.650 kg = (8010 7946) / 8010
= 0.9920
Scrap (Trimmed flash) : 0.060 kg Quality Rate = 99.2%
Production/day (3.50X10) : 8000 Nos.
Production/day (All sizes) : 25000 Nos.
Performance
Time (Min.)
Processing
Output of
Machines
Machine
TABLE II
Process
Actual
Rate
AVAILABILITY CALCULATION IN PARALLEL MACHINES
Equivalent
Failure rate/Min. j
is working Pwj
is down Pdj
Calendaring Extruding
0.894075
Machine
Process
E-01
0.1572 8190
MTTReq
MTBFe
Aeq
eq
eq
BM-(01-02) CA-(01-03)
0.4277
0.0752 8190
1 24 0.98 0.02 0.014
2 26 0.97 0.03 0.02
0.457275
Making
Bead
3 22 0.99 0.01 0.025 0.0804 8190
4 25 0.96 0.04 0.022
Tyre Builder
74.6148
0.1964
0.5111
0.0134
0.9744
5 24 0.98 0.02 0.021
0.50789375
TB-(01-10)
Building
Tyre
6 27 0.97 0.03 0.019
0.0893 8190
7 22 0.99 0.01 0.018
8 25 0.97 0.03 0.019
Vulcanizing
TV-(01-20)
0.41405
9 26 0.96 0.04 0.018
0.0728 8190
10 24 0.98 0.02 0.025
1 14 0.98 0.02 0.028
2 16 0.97 0.03 0.026
D. Overall Equipment Effectiveness Calculations.
3 16 0.96 0.04 0.027 TABLE IV
OEE CALCULATION
4 14 0.98 0.02 0.029
Performance
Availability
Quality
Process
E-01
0.002894
10.4058
345.515
0.09609
CA-(01-03)
BM-(01-02)
TABLE III
TV-(01-20)
From above OEE calculation, performance rate of all the The solutions are given below for the better performance
machines are poor except Extruding machine. That is of an each machine. While optimizing the Overall
below 95%. Above 95% is considering as a better Equipment Effectiveness (OEE), the calculated values are
performance of a machine. considered as a minimum value and expected values are
V. PROBLEM IDENTIFICATION considered as a maximum value of OEE. The below table
shows the optimized values of OEE. It is done by Solve
From above OEE calculation, performance rate of all the XL. To optimize the value of OEE, the Genetic Algorithm
machines are poor except Extruding machine. That is is used and optimized values are merged in an Excel sheet
below 95%. Above 95% is considering as a better for each machine.
performance of a machine. B. Optimized values of OEE by GA.
Here we need to increase the performance rate for each
TABLE V
machine. Genetic algorithm is used to optimize the
OPTIMIZED OEE VALUES
performance rate for each machine. Solve XL an excel
Machine
Process
Add-Ins for Genetic Algorithm is used to optimize the
A PR QR OEE Fitness
OEE values.
The following are the expected values for each OEE
factors 89 87 99 76.6557 76.6557
Availability 90 % 90 85 99 75.735 75.735
Performance Rate 95 % 89 85 99 74.8935 74.8935
99.9 % 90 79 99 70.389 70.389
Calendaring
Quality Rate
CA - (01-03)
90 79 99 70.389 70.389
VI. SOLUTION 89 75 99 66.0825 66.0825
A. Genetic Algorithm. 88 75 99 65.34 65.34
An algorithm is a set of instructions that is repeated to 88 73 99 63.5976 63.5976
solve a problem. A genetic algorithm conceptually 90 69 99 61.479 61.479
follows steps inspired by the biological processes of 90 47 99 41.877 41.877
evolution. Genetic Algorithms follow the idea of 90 95 99 84.645 84.645
SURVIVAL OF THE FITTEST- Better and better 90 79 99 70.389 70.389
solutions evolve from previous generations until a near 90 75 99 66.825 66.825
optimal solution is obtained. Also known as evolutionary 90 75 99 66.825 66.825
Bead Making
90 75 99 66.825 66.825
BM - (01-02)
90 91 99 81.081 81.081
TB - (01-10)
90 91 99 81.081 81.081
90 89 99 79.299 79.299
90 89 99 79.299 79.299
90 89 99 79.299 79.299
90 89 99 79.299 79.299
90 87 99 77.517 77.517
90 95 99 84.645 84.645
90 59 99 52.569 52.569
90 58 99 51.678 51.678
90 58 99 51.678 51.678
89 58 99 51.1038 51.1038
TB - (01-20)
Vulcanizing
89 58 99 51.1038 51.1038
90 57 99 50.787 50.787
90 57 99 50.787 50.787
89 57 99 50.2227 50.2227
89 49 99 43.1739 43.1739
90 48 99 42.768 42.768
90 95 99 84.645 84.645
Fig. 2 Flow chart of a Genetic Algorithm
VII. CONCLUSION
As OEE is an important performance measure for
effectiveness of any equipment, careful analysis is
required to know the effect of various components. A
excel sheet can be used as simplest tool to measure and
monitor true data collection. An attempt has been done in
this study to optimize the OEE by using Genetic
Algorithm (GA). This study indicates that OEE will be
significantly improved if focus is given on performance
rate improvement. To achieve the OEE of 84.645%,
optimized values are Availability 90%, Performance Rate
95% and Quality Rate 99%. Simulated values of above
scenario will add more valuable information to industry.
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