HOMEWORK 3

Question: Production cell with the following conditions

Working time: 3 shifts/day, 5 days/week. Shift hours: 6:00 – 14:00, 14:00 – 22:00, 22:00 – 6:00
Planning related stops (no production):
- Breaks: 30 minutes each shift
- Meetings: Every Thursday 13:30 – 14:00
- Preventive maintenance: daily during shift exchange at 6:00 - 6:15, 14:00 – 14:15, 22:00 - 22:15
- Production: cycle time 9 minutes/item
True outcome during one week:
- Breakdowns: Mon: 6:30 - 10:00; Tue: 9:00 – 10:12, Wed: 20:30 - 21:48; Fri: 14:30 – 17:18
There are 553 items produced of which 8 were scrap
Calculate OEE, MTBF, MTTR for that week

Solution:
We have:
Working time: 3 shifts/day, 5 days/week
Shift hours: 6:00 – 14:00, 14:00 – 22:00, 22:00 – 6:00
=> Total available time = 3 * 5 * 8 = 120 (hours)

We have:
Breaks: 30 minutes each shift
→ Total breaks time a week = 30 * 3 * 5 = 450 (mins) = 7.5 (hours)
Meetings: Every Thursday 13:30 – 14:00
→ Total meetings time a week = 0.5 (hours)
Preventive maintenance: daily during shift exchange at 6:00-6:15, 14:00 – 14:15, 22:00-22:15
→ Total preventive maintenance time a week = (15+15+15) * 5 = 225 (mins) = 3.75 (hours)
Breakdowns: Mon: 6:30-10:00; Tue: 9:00 – 10:12, Wed: 20:30 -21:48; Fri: 14:30 – 17:18
→ Total breakdowns time a week = 210 + 72 + 78 + 168 = 528 (mins) = 8.8 (hours)
=> Total downtime = 7.5 + 0.5 + 3.75 + 8.8 = 20.55 (hours)

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 𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒−𝑡𝑜𝑡𝑎𝑙 𝑑𝑜𝑤𝑛𝑡𝑖𝑚𝑒 120−20.55
Availability = = = 82.875%
𝑡𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 120

We have:
Production: cycle time 9 minutes/item
There are 553 items produced
60×(120−20.55)
Total items that can be produced = = 663 (𝑖𝑡𝑒𝑚𝑠)
9

Produced items 553

Performance = Total items that can be produced = 663 = 83.4%

We have:
There are 553 items produced of which 8 were scrap
Produced items − defeted items 553−8
Quality = = = 98.55%
Produced items 553

We have:
• OEE = availability × performance × quality = 82.875% × 83.4% × 98.55% = 68.11%
120 − 20.55
• MTBF = Total uptime/Number of failures = = 24.8625
4

(number of failures = number of breakdowns)

8.8
• MTTR = Total downtime/Number of failures = = 2.2
4

(total downtime = total breakdown time)