Overall Equipment Effectiveness (OEE) and Overall Plant Efficiency (OPE)

Overall Plant Effectiveness (OPE) is the ratio in percentage of
Actual Accepted Quantity Produced (Q2) to the Quantity that should have been produced in Total Scheduled Hours (T2xN)
That is, OPE = {Q2/T2xN}x100%
And, similarly,
Overall Equipment Effectiveness (OEE)
Is the ratio in percentage of
Actual accepted quantity produced (Q2) to the Quantity that should have been produced in Total Loading Hours (T3xN)
That is, OEE = {Q2/T3xN} x100%
(Where N is the 100% Rated Output per Hour)

Overall Equipment Effectiveness (OEE)
Can also be expressed as
OEE = Availability x Performance Rate x Quality Rate
Where,
Availability is the ratio in percentage of
Total Operating Hours (T4) to Total Loading Hours (T3)
Performance Rate is the ratio in percentage of Actual Quantity Produced (Q1) to Quantity that should have been produce in Total Operating Hours (T4)
Quality Rate is the ratio in percentage of
Actual Accepted Quantity Produced (Q2) to Actual Quantity Produced (Q1)

16 - YEILD LOSS

These are volume losses stemming from weight differences between raw materials and products or between all raw material input and the products.
The former are material losses caused by increasing wall thickness to more than the necessary level, in order to prevent casting defects (sand inclusion, surface flaws) in the raw materials or to cover the insufficient precision of shaping moulds. These losses sometimes cause the extension of machining time or the reduction of the service life of cutting blades.

The latter represents the difference between slag weight/gate weight/burr volume and product weight-material losses causing yield decline due to increased burr occurrence resulting from insufficient mould precision. In aluminium casting, the weight of runner and burr is applicable instead of the above weights.

This affects cost & not affecting the equipment OEE / OPE

15- DIE,JIG & TOOL LOSS

These are monetary losses resulting from the manufacturing and repair of dies, jigs, and tools necessary for the production of products.

Die, jig, and fixture losses represent expenses arising as a result of manufacturing of new moulds, replacement due to the end of service life or breakdown, repair following wear, manufacturing or repair of mould parts, and manufacturing or repair of jigs and tools. If the repair frequency is high, expenses naturally grow


This affects cost & not affecting the equipment OEE / OPE

(14) Energy Loss

These are losses of such energy as electric power, fuel, steam, air, and water (including wastewater).

Improvement has been achieved with regard to major energy losses, but a considerable number of minor losses are left un-rectified, so there is much room for improvement. In the case of hydraulic equipment, various problems must be detected by studying the following points:

- Is the pressure-setting appropriate?
- Is the holding time appropriate?
- Is the hydraulic pump type suitable (variable capacity type)?
- Is the hydraulic circuit suitable?

Detected problems should be solved one by one. Finding and improving many minor energy losses adds up to great results.

This affects cost & not affecting the equipment OEE / OPE

(13)Measuring and adjustment losses

These are worker-hour losses that result from frequent implementation of measuring and adjustment to prevent occurrence of quality defects and flow-out.
This affects Availability, OEE & OPE.

(12)Logistics loss & failure to automate

These are personnel losses resulting from non-replacement with automated systems, although such replacement could be done. They include, for instance, cases in which automated loading and unloading leading to manpower reduction is not implemented, although it could be done. Also in this category are distribution losses, which occur because automation of distribution operations such as supply, shipment, and transport of parts and products is not enforced although it is possible.
This affects Availability & OPE

(11)Line organisation losses

• These are waiting time losses involving multi-process and multi-stand operators and line-balance losses in conveyor work.
• This affects Availability, OEE & OPE