Overall Equipment Effectiveness Definition

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  • Topic: Availability, Volume, Overall equipment effectiveness
  • Pages : 11 (1038 words )
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  • Published : August 26, 2011
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ETHYLENE MALAYSIA SDN BHD POLYETHYLENE MALAYSIA SDN BHD

TOOLS DOWN: OVERALL EQUIPMENT EFFECTIVENESS (OEE)

What is Tools Down?

An activity where certain tools or knowledge is shared with a person or group of people with the intent to upskill those people in the usage of the tool or develop deep understanding of how the tool is utilized

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

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OVERALL EQUIPMENT EFFECTIVENESS (OEE)

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

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Definition

OEE is used to measure plant performance against its limit and identify sources of loss within the plant. It measures how well we use the equipments when they are available.

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

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To understand OEE better is to understand OEE waterfall chart…

y
External factors Category 3* -i.e., lack of demand, lack of feed, lack of storage and other external downtime Slowdown S2 – Slowdown (external upstream) S3 – Slowdown (external downstream) S4 – Slowdown (Others/ force majoure) Not Normal Plant Operations 2a* - Debottle necking 2b* - Revamp/ Rejuvenation

Formula:

This model is based on the latest OEE concept approved and endorsed during 36 th OPI Working Group Meeting and 61st Plant Managers Meeting. * As per the IPWE classification of downtime ** As per the OPI definition for OEE calculation *** In cases where the MSR is lower than Nameplate Capacity, Nameplate Capacity will be used instead of MSR

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

Maximum Sustainable Rate***

OEE
Turnaround (DOSH requirements)

Net Production (x) Adjusted Capacity (y)

Adjusted Capacity**

Normal Plant Operations 1a* - Scheduled downtime (excluding Turnaround)

Available Capacity**

Normal Plant Operations 1b* - Unscheduled downtime 1c – Consequential downtime

Slowdown S1 – Slowdown (internal)

x
Net Production**
Quality (Reject or off spec.)

Gross Production**

Indirect losses

Availability losses

Productivity losses

Quality losses

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What is Maximum Sustainable Rate (MSR)?

Maximum Sustainable Rate (MSR): OPU specifies its respective MSR for a period based on the highest daily throughput or production rate sustained over 30 consecutive days. In cases where the MSR is lower than Nameplate Capacity, Nameplate Capacity will be used instead of MSR.

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

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External factors – Indirect losses

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

Maximum Sustainable Rate

Category
Not Normal Plant Operations Category 2* Downtime

Definition Debottlenecking Revamp/Rejuvenation Lack of economic feedstock Economics Lack of storage Others Slowdown (external upstream) Slowdown (external downstream) Slowdown (Other/Force Majeure)

2a 2b 3a

External Factors Category 3* - Downtime Category S* - Slowdown

3b 3c 3d S2 S3 S4

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Internal factors – Downtime (Availability losses)

Turnaround

Category Turnaround
Normal Plant Operations Category 1b & 1c Normal Plant Operations Category 1a

Definition

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

Adjusted Capacity

1a 1b 1c

Planned downtime Unplanned downtime Consequential downtime

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Internal factors – Slowdown (Productivity losses)

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

Available Capacity

Category
Category S1

Definition Slowdown (Internal)

S1

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Internal factors – Slowdown (Quality losses)

ETHYLENE MALAYSIA SDN BHD & POLYETHYLENE MALAYSIA SDN BHD

Gross Production

Net Production

Category Quality loss

Definition

Quality Reject, offspec, flaring (Not applicable to EPEMSB)

Official production as recorded by Production Planner

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Recap…

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External factors: Downtime 3a – Lack of economic feedstock 3b – Economics 3c – Lack of storage 3d - Others Slowdown S2 – Slowdown...
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