Rationale

In industrial plants, production efficiency problems are often not solely due to machine breakdowns, but also include minor downtime, slower-than-standard operation, in-process waste, lengthy setup times, and unsystematic on-site data recording. These issues frequently become "hidden costs" that result in actual production capacity falling below the plant's potential

The OEE (Overall Equipment Effectiveness) concept is a crucial tool for measuring the efficiency of machinery and production processes. It analyzes three main components: Availability, Performance, and Quality, and links it to the TPM (Total Productive Maintenance) concept. This allows production and maintenance teams to identify problems collaboratively, pinpoint losses, and plan concrete improvements.

This course is therefore designed as a practical training program that focuses not only on theory, but also allows participants to practice calculating OEE, analyzing Six Big Losses, designing data collection methods, and creating action plans that can be immediately applied to real-world situations

objective

Upon completion of the course, trainees will be able to:

• Understand the meaning and importance of OEE to production efficiency
• Accurately explain the components of OEE, namely Availability, Performance, and Quality
• OEE can be calculated from actual production data or case studies
• Analyze the Six Big Losses to identify the main losses in the production process.
• Systematically categorize downtime, speed loss, and quality loss issues
• Design an OEE data collection methodology that is appropriate for the machinery or production process
• Use the Pareto and Vital Few concepts to select areas for improvement that yield high results
• Develop an action plan to reduce losses and improve on-site efficiency

Who is this course suitable for?

This course is suitable for personnel involved in manufacturing, process improvement, and machine maintenance, including:

• Production Supervisor
• Process Engineer
• Maintenance technicians and maintenance team
• Production or operations manager
• Continuous Improvement / Lean / Kaizen Team
• Production planning officer
• Those who want to start using OEE to analyze plant performance

Benefits to be received

Participants will benefit from the training in terms of knowledge, tools, and practical application, as follows:

• Analyzing production problems accurately
• It's possible to identify whether the main problem stems from downtime, speed loss, or quality loss, and to be aware of hidden costs and losses in the factory.
• Understanding the concept of a Hidden Factory and the losses often overlooked in typical production reports can help reduce downtime and increase machine efficiency.
• Identifying the causes of machine downtime and defining clear solutions increases productivity without the need for immediate investment in new machinery.
• Focuses on using data and process improvement to increase productivity from available resources, systematically linking OEE with TPM.
• Understand the roles of production and maintenance teams in maintaining machine efficiency . Participate in workshops using case studies.
• Practice calculating OEE, analyzing Six Big Losses, and developing an Action Plan. Apply the knowledge immediately back to the factory.
• Includes templates for collecting OEE data, an OEE calculator, and an action plan

If you are facing these problems, this course can help you

• Production was below target, but it's unclear where the losses occurred
• High downtime, but the cause is not yet clearly identified
• Production data is available, but it cannot be analyzed yet
• The current machinery is inefficient, but we don't want to invest in new equipment yet
• The production and maintenance teams are viewing the problem from different perspectives

Course Details / Course Outline

Module 1: OEE Fundamentals

• What is OEE?
• Why is OEE a key indicator of production efficiency?
• The concept of World-Class OEE
• Hidden Factory and the Hidden Costs in the Factory
• OEE and organizational competitiveness

Workshop/Activity:
Analyze which machinery or process problem is causing the most costs for the factory.

Module 2: The Three Components of OEE

Learn the three main components of OEE

1. Availability
measures losses from machine downtime, such as breakdowns, changeovers, setup, and downtime.

2. Performance
measures losses due to speed, such as minor stops, reduced speed, idling, and operation below standard.

3. Quality
measures losses from defects such as Startup Reject, Process Defect, Scrap, and Rework.

The basic formula is:
OEE = Availability × Performance × Quality

Workshop/Activity:
Practice classifying problems using simulated factory scenarios to determine how each type of problem affects Availability, Performance, or Quality.

Module 3: Six Big Losses Analysis

Learn to analyze the 6 main types of losses that impact OEE, including:

1. Equipment Failure
2. Setup & Adjustment
3. Idling & Minor Stops
4. Reduced Speed
5. Startup Defects
6. Process Defects

The content will help trainees understand how each type of loss is related to Availability, Performance, and Quality, as well as the relationship between OEE and TPM

Workshop/Activity:
Practice mapping on-site problems to the Six Big Losses to identify losses that should be prioritized.

Module 4: OEE Calculation Workshop

• A systematic process for calculating OEE
• Calculating Planned Production Time
• Calculating Run Time
• Availability calculation
• Performance calculation
• Calculating Quality
• Interpreting OEE results
• Identifying areas for improvement based on the calculated values

Workshop/Case Study:
Participants practice calculating OEE (Overall Equipment Effectiveness) using production case studies, such as shift hours, break times, planned downtime, actual production volume, waste quantity, and ideal cycle time.

Module 5: OEE Data Collection

• Information required for OEE calculation
• Collecting Downtime Data
• Collecting data on production and waste
• Collecting Cycle Time Data
• Distinguishing between Planned Downtime and Unplanned Downtime
• Methods for collecting data include Manual Logs, Operator Entry, Machine Automation, and OEE Software
• Common errors in OEE data collection

Examples of common errors

• Count Planned Downtime as Unplanned Downtime
• Minor Stops are not recorded
• Using an incorrect cycle time
• There's confusion between Shift Time and Production Time

Workshop/Activity:
Design an OEE data collection form for machinery or processes that the trainees actually use.

Module 6: OEE Improvement Strategies & TPM

• Using Pareto Analysis to select the key problem
• Focusing on Vital Few Losses
• Setting appropriate OEE (Overall Equipment Effectiveness) targets
• Solutions for Equipment Failure
• A method to reduce setup and adjustments using SMED
• Guidelines for Reducing Idling & Minor Stops
• Solution: Reduced Speed
• Guidelines for reducing startup defects and process defects
• The Role of the Operator in Autonomous Maintenance
• The role of Maintenance in Preventive and Predictive Maintenance
• Creating a Visual Management Board
• Daily Accountability Meeting
• Creating a Culture of Continuous Improvement

Workshop/Activity:
Participants will choose one major problem from their own work and develop an action plan to improve it within 30 days.

lecturer

There are two instructors who take turns in the training sessions

Professor Pisit Chuyong

Our Lean and Factory Management expert has over 32 years of experience in the textile, automotive, and beverage industries, including 18 years of experience in Lean-Kaizen Consulting & Training and 7 years as an International Consultant to ITC/UNCTAD

Professor Suwan Sutthijarakit

An expert in Lean Manufacturing, OEE, TPM, Kaizen, and productivity improvement in the food and consumer goods manufacturing industries, with over 25 years of experience. Author of the book "Manufacturing KPIs for TPM," and consultant to over 26 food factories