Modelling overall equipment effectiveness improvement with overall production cost

Tam, Yau Yin (2016) Modelling overall equipment effectiveness improvement with overall production cost. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Overall Equipment Effectiveness (OEE) is a system measurement for the total equipment performance, in which requires to specify an equivalent weight setting for every single parameter, even though; each elementary losses are totally different. Hence, the purpose of this research project is to develop a mathematical model to determine the dissimilarity in weighting of each OEE factor for the THA Taper Machine. This study focuses on how much improvement in each OEE factor on the machine is able to reduce the overall production cost. Total Fabrication Monitoring (TFM) system is conducted to collect the data from the system database to determine the current OEE percentage of the machine. In addition, the data collected is analyzed using the Excel tools to determine the relationship of each data. This analysis is then developed to identify the range of weightage for each OEE parameter to be proceed on the Forecasting analysis. Through the Forecasting analysis using Mean Absolute Deviation (MAD), the most suitable weightage for each parameter is determined by selecting the OEE weightage combination with least error. Rauof method is used to develop the mathematical model by referring to selected OEE weightage combination to determine weightage of each OEE factor on the machine to the overall production cost. According to the result obtained, Availability (AV) appears to be the critical cause toward low OEE percentage of the machines and thus improvement action should be focus on AV in order to increase the highest percentage of OEE. Machines throughput was proved to be directly proportional to the OEE and increasing in the throughput will decrease the overall production cost. Hence, the production cost can be reduced as the OEE was improved. Improvement plans related to THA Taper machines can be propose by referring to the mathematical model developed.

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