Common reasons for sub optimal oee (SOE)

Owned by Edward Barrier (Unlicensed)
Last updated: Dec 11, 2023
2 min read

Plant Focus can track sub optimal running of your equipment. We do that by tracking:

  • Realtime Production Rate

    • PPM, TPH, Cycles, etc.

  • Realtime RUNNING / NOT RUNNING condition

  • Product Type

We create downtime events (DTE) based upon the running condition. _Downtime Module

We know the min, max and target production rates. _Recipes

When below a specified threshold identified in the recipe AND the equipment is running, we will log a “Sub Optimal” event (SOE). If the equipment stops, the SOE stops and a DTE begins. Summing operating hours, DTE and SOE hours will always be 24 in a single day. (Aside from daylight savings)

 

OEE (Overall Equipment Effectiveness) is a key performance indicator used in manufacturing to measure the efficiency and productivity of equipment or production processes. Sub-optimal OEE indicates that the equipment is not performing at its full potential. Several common reasons for sub-optimal OEE include:

  1. Equipment breakdowns: Frequent breakdowns or unplanned downtime can significantly reduce equipment availability and, consequently, OEE.

  2. Setup and changeover times: Lengthy setup and changeover processes between different products or tasks can lead to reduced production time and lower OEE.

  3. Reduced speed: If the equipment is not running at its designed or expected speed, it can decrease the overall production rate and negatively impact OEE.

  4. Quality issues: Defective or inconsistent product output can lead to lower OEE due to increased waste, rework, or rejected products.

  5. Material shortages: Lack of raw materials or other inputs can cause production delays and lower equipment utilization, affecting OEE.

  6. Lack of operator training: Inadequate training or unfamiliarity with equipment can result in improper operation and decreased efficiency.

  7. Preventive maintenance: Neglecting regular maintenance can lead to more frequent breakdowns and reduced equipment availability, negatively impacting OEE.

  8. Unplanned maintenance: Reactive maintenance, where issues are addressed after they occur, can lead to longer downtimes and lower OEE compared to planned maintenance.

  9. Production scheduling: Poorly planned production schedules may result in inefficient use of equipment, leading to increased idle time and lower OEE.

  10. Poor process design: Inefficient workflows or processes can result in bottlenecks, uneven workloads, and reduced overall equipment effectiveness.

  11. Lack of real-time data: Without accurate and timely data on equipment performance, it can be challenging to identify issues and make informed decisions for improvement.

  12. Human error: Errors made by operators or maintenance personnel can lead to disruptions and reduced equipment efficiency.

To improve OEE, manufacturers often employ continuous improvement methodologies, such as Lean or Six Sigma, to address these issues and optimize equipment performance. By identifying and addressing the root causes of sub-optimal OEE, companies can increase productivity, reduce downtime, and enhance overall equipment effectiveness.