Optimizing Overall equipment effectiveness through simulation analysis

DOI: 10.5176/2251-1938_ORS18

Authors: Anand S. Relkar and K. N. Nandurkar

Abstract:

To compete in the global market, under utilization of machines is not at all affordable. In such scenario performance measurement is essential to know the state of art. Nakajima in 1988 introduces concept of Total Productive Maintenance in which focus is on continuous improvement of machine to achieve zero breakdown through autonomous maintenance. Overall Equipment Effectiveness is a performance measure metrics of equipment which will helps to reduce losses and improve overall equipment effectiveness (O.E.E.) of machines. It measures breakdown and other related losses (speed losses, rejection) quantitatively. Overall equipment effectiveness (OEE) is a product of availability rate, performance rate and quality rate of machine. But while applying, manufacturer observed that OEE varies with nature of industry and with respect to application. Researchers in this field also feels that only effectiveness of single equipment will not serve the purpose of higher productivity but impact of one machine on another must also be taken into consideration. Each critical machine must maintain world class overall equipment effectiveness about 85{6e6090cdd558c53a8bc18225ef4499fead9160abd3419ad4f137e902b483c465} to improve overall factory effectiveness. In this paper an attempt has been done to simulate a manufacturing scenario by using WITNESS software to identify bottleneck machine. Experimentation has been done by using simulation software WITNESS. Different combinations of mean time between failures and repair time results into variation in output. MiniTab15 software is used for regression analysis which establish relation between overall equipment effectiveness and time between failure, repair time. The process of overall equipment effectiveness is optimized by using response surface methodology to identify optimized zone for maximizing output.

Keywords: Overall equipment effectiveness (OEE), Simulation WITNESS, MiniTab15, optimization, maximum output.