Shift Report

Line: ___________________ Shift: _____

Date: ___________________

No. Startup & Planned Downtime Number of Other Number of Breaks in Documentation of events Code Station
changeover downtime (mins) occurrences downtime other faults minutes
time (mins) (mins) (mins)

10

Codes for fault types: Number of parts manufactured

M = mechanical: P = pneumatic, H = hydraulic, O = operator error, M = maintenance fault Number of parts defective /rework

Working hours Stoppages (min) Breakdown (min) Breaks (mins) Cycle times Parts / min

Loading time = ................ - ................ = ............... Loading time Standard cycle time ..........

Operating time = ................ - ................ - ................ - ................ = ............... Net operating time Actual cycle time ..........

Availability Performance Rate Quality Products Rate

OEE net operating time
loading time
Planned cycle time x no. of parts produced
Net operating time
No. of parts produced - rework - reject
No of parts produced
x 100 = OEE
Overall = x 100 X x 100 X
Equipment ....... % ....... % ....... % x 100 = OEE
Efficiency of .........%

© Festo Didactic GmbH & Co. • Manufacturing Excellence Training - Hanover Fair 2001 1
Shift Report
Line: ___________________ Shift: _____
Date: ___________________

List of faults

No. Date Tiime Fault Cause Fault Corrected by Measures taken Downtime
Type (Name) (mins)

1 15 10.14 Magazine cylinder stuck in out position Supply line bent P Indy Jones Line replaced, re-routed and secured 7

2 15 14.03 Vacuum not working Suction filter blocked P Jimmy Bond Filter cleaned 9

3 15 16.37 Could not reset station Auto/ Man switch defective E Jimmy Bond Switch replaced 5

4 16 8.51 Mag cylinder works with no parts in mag Magazine sensors misaligned M Indy Jones Sensor adjusted 6

5 16 9.33 Station does not start No program in PLC due to power out E Jimmy Bond Program downloaded 9

6 16 16.56 Parts falling from suction cup Suction filter blocked P Indy Jones Filter replaced 8

7 17 07.03 Magazine cylinder does not extend Connection on the output of PLC burnt out E Indy Jones Connector replaced, reconnected 12

8 17 10.14 Vacuum too weak Filter blocked P Jimmy Bond Filter removed 6

9 17 11.55 Short circuit on 3S1 Switch dirty E P. Anderson Switch replaced 5

10 18 06.38 Rotary arm does not operate Faulty connection on control valve E Indy Jones Connection repaired 18

11 18 14.35 Station does not react No program in PLC E Indy Jones Program downloaded 14

12 19 15.23 Station stopped Pressure drop in system due to dirty filter unit P Jimmy Bond FRL cleaned 24

13 20 08.11 Rotary cylinder does not move in Sensor 1B1 badly adjusted E/M Indy Jones Sensor adjusted 8

14 20 13.19 Vacuum not being generated properly Filter missing, vacuum generator defective P P. Anderson Generator replaced, filter fitted 8

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Line: ___________________ Shift: _____
Date: ___________________

Example of Overall Equipment Calculation

Explanation Example Calculation

A Working hours Number of working hours x 60 mins 8h x 60 = 480 mins

B Planned downtime per day e.g. for scheduled maintenance, meetings etc 20 mins

C Loading time per day A–B 460 mins

D Stoppage losses per day Breakdowns, setup, adjustment 3 x 20 mins = 60 mins

E Operating time per day C- D 400 mins

G Output per day Number of items produced 400

H Rate of quality of products Ratio of good to reject or rework products 98%

I Ideal cycle time Cycle time for one part e.g. 0.5 min / part

J Actual cycle time Average cycle time for a part 0.8 min / part

Therefore

Explanation Example Calculation

F Actual processing time Actual cycle time x output per day, JxG 0.8 x 400 = 320

T Availability Operating time per day /Loading time per day, E/Cx100 400/460x100 = 87%

M Operating speed rate Ideal cycle time / actual cycle time x 100, I/J x100 0.5/0.8x100 = 62.5%

N Net operating rate Rate of quality of products / Operating time per day x 100, F/E x 100 (0.8 x 400) /400 x100 = 80%

L Performance efficiency Operating speed rate / Net operating rate x 100, MxNx100 0.625 x 0.8 x 100 = 50%

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Line: ___________________ Shift: _____
Date: ___________________

Definitions
Operating speed rate Theoretical cycle time / actual cycle time
Operating rate Ratio of operation time excluding downtime to loading time
Availability Loading time – downtime / loading time
OR
Operating time / loading time
Net operating time Standard Cycle time X Units Produced / Operating time X 100%

Net operating rate Units produced x Actual cycle time /Loading time - Downtime
Rate of quality of products Units produced – defective units / units produced X 100%
Performance Rate Standard cycle time x Units produced / Operating time
Operating speed rate x Net operating rate

OEE Availability x Performance Rate x Quality Products Rate

Performance efficiency net operation rate x operating speed rate

Net operation rate actual processing time/ operation time
processed amount x actual cycle time / operation time

Rate of quality processed amount – defect amount / processed amount x 100

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Shift Report
Line: ___________________ Shift: _____
Date: ___________________

Current Changeover Sequence

Step No. Internal External Move from Int to Ext Parallel operations Time / Step Aids Remarks

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Line: ___________________ Shift: _____
Date: ___________________

Planned Changeover Sequence

Step No. Internal External Move from Int to Ext Parallel operations Time / Step Aids Remarks

© Festo Didactic GmbH & Co. • Manufacturing Excellence Training - Hanover Fair 2001 6