The key indicator that will tell you everything about your industrial plant efficiency The selection of the appropriate metric can make the difference between the success and failure of the operational strategy Within the culture of continuous improvement, industrial companies that intend to migrate to industry 4.0 and optimize their production processes need to work on the identification and, subsequently, the elimination of waste and activities that do not add value to their operation. This is possible if the origin of production losses is known and understood and concrete actions are taken to reduce them consistently and permanently until they are eradicated. A simple metric, easy to communicate; and universally accepted; is the OEE (Overal Equipment Effectiveness) or Global Equipment Efficiency; indicator that allows us to measure how close we are to a perfect production system, that is, when only good parts are manufactured, as quickly as possible, without downtime.
Through the OEE it will be possible to know the status of a single machine, a production line or a complete plant, establish objectives and measure the result of the proposed improvements. This metric encompasses, in a single indicator, three important dimensions within industrial productivity: a) availability, b) performance and c) quality, whose concepts are related to the Six Big Losses that can occur in a machine and take it away from its effectiveness. OEE = Availability * Performance * Quality Availability: It is a measure of machine losses due to scheduled and unscheduled stoppages. It relates the total planned production available time to the time a machine was actually running.
AVAILABILITY = Execution time / Planned production time Yield: It is a measure of the losses caused by the malfunction of the machine while it is producing. It refers to the correct use of the machine while it is operational. PERFORMANCE = (Ideal cycle time * total pieces produced) / Execution time Quality: It is a measure of the total production that is produced without defects, complying with quality standards. QUALITY = Compliant parts / total parts produced
Each one of the terms that make up the OEE is measured as a percentage, therefore it is situated between values between 0% and 100%. The low end, OEE = 0%, represents total unproductiveness and the high end, OEE = 100%, represents total excellence. Carrying these concepts, which may initially be abstract, means deeply training plant operators and supervisors to achieve an understanding of how their daily activities affect OEE and motivate them to achieve objectives, the results of which lead to an increase in its percentage value. . This is enhanced when operators and supervisors can see results in real time, with the help of technological tools that facilitate the flow of data extraction from the physical world and take it to the digital world as information available for decision making at the right time.
All the proposed calculation scheme can be cumbersome and expensive if it is done manually. Tools like Wiibiq's Factory Performance Booster solve the problem easily. Current times require making effective and efficient decisions. Through digital monitoring of productive management, it is possible to do so.