Foreword
Preface
Acknowledgements
1. Understanding the Power of
Overall Equipment Effectiveness (OEE)
1.1 Factories: Effective Producers of Good Goods
1.2 Factory Dynamics
1.3 Balancing the Business
Decide II: A Simulation Experience
1.4 Leadership for Teams
1.5 Moving the Community to Improved Performance
A Case Study Using OEE Metrics
1.6 Total Effectiveness Equipment Performance
(TEEP)
1.7 The Bottom Line: Good Goods at Lowest Cost—Now!
2. Learning the Basics of OEE
Metrics
2.1 Definitions of OEE Categories
2.2 Data Collection Review
2.3 Practice Production Report
2.4 Summarization Example
2.5 OEE Formulas and Results
Method 1 OEE Using Nakajima Formulas
Method 2 OEE Using Event Time Records
Method 3 OEE Based On Good Units Transferred
2.6 Reconciliation and Loss Analysis
3. The Financial Aspects of
OEE
3.1 Factory Example: Base Case
3.2 Case B: Same Output, Improved OEE
3.3 Case C: Full Factory, Improved OEE
3.4 Case D: OEE Impact on Return On Assets (ROA)
3.5 Case E: Higher OEE with the Same Sales, ROA
3.6 Case F: Higher OEE, Selling Everything Produced,
ROA
4. The People Factor 67
4.1 The Most Important Resource: Actively
Learning, Motivated People
4.2 Group Centering Exercise The Metronome Exercise
4.3 Skills, Interaction, Action
4.4 Observation and Education
4.5 Work Group Experiences
4.6 An Example of Expectations: Master Mechanics
4.7 An Example of Expectations: Technicians
4.8 Interviewing and Hiring
4.9 Ranking and Compensating
5. Priority and Decision
Tools
5.1 The Value Fulcrum
5.2 Developing a Troubleshooting Guideline Decision
Tree
6. Win-Win
Maintenance/Equipment Shutdown Strategies
6.1 Steps to Improve TEEP: A Case Study
Identify
Exploit
Subordinate
Elevate
Go back
6.2 Shutdown Strategy Checklist
7. Reliability
7.1 Reliability101 Introduction
7.2 Reliability Nomenclature
7.3 Beginning Reliability with What You Have
7.4 Matching Maintenance Strategy to Equipment
Function
7.5 Developing Best Practices
7.6 Building Reliability into Equipment Design
8. Reliability Availability
Maintainability/System Performance Analysis, (RAM/SPA)
8.1 RAM/SPA
8.2 Improving the ‘Horse’ you Already Have /
Starting Reliability
8.3 Quick Changeovers: Single-Minute Exchange of
Dies
8.4 Theory Of Constraints
8.5 Data collection and Information sharing
8.6 Pareto Analysis
8.7 Project Management and Asset Life Cycle
8.8 Speed ups
8.9 Cycle time improvements
8.10 Benchmarking
9. A General Tool for
Acceptance Testing
9.1 Reliability Quantification Testing
9.2 Implementation Stories
Case 1. Barrel Dumper Project
Case 2. Computer System Upgrade
Case 3. Material Handling Wheels
Case 4. Automatic Core Loading
10. Success or Failure
10.1 The Success Riddle
10.2 Why Factories Fail
Impending Failure Study
APPENDIX
1. Recommended Reading
2. RAPTOR
3. Redundancy Equations
4. Generic Failure Rates
5. Mechanical Failure Modes
6. Failure Mode Effects and Criticality Analysis
7. Constructing Pareto Charts
8. Preserving Failure Data
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