Equipment Performance

Monitoring

Availability Utility
EE
O

TO
A
Productivit
y Reliability
 Availability

Availability is the measure of downtime of equipment, i.e how much

the equipment is available for use.

Total Hours in a month –

Breakdown Hours
Availability % = x100
Total Hours in a month

During Nov’09 ,a wheel loader at Bhushan Steel Job was under

breakdown for , 3 days i.e. 72 hrs.
What is the availability % ?
(24 hrs x 30 days) – 72 hrs 720-72
Availability = = x 100 = 90% (24 hrs x
30 days) 720
 Utility

Utility is the measure of actual usage of equipment. It is normally

measured on a 12 hrs clock.

Hours Worked
Utility % = x100
26 days x 12 hrs a day

During June’09 ,one 500 kva Power Generator has run for 250 hrs.
What is the Utility % ?

250 hrs 250

Utility % = = x 100 = 80% (24 hrs x 30
days) 312
 Reliability

Reliability is the probability that an equipment performs its intended

function for a stated period of time, under specified operating
conditions.It is measured as MTBF.

Hours Run
Reliability(Hrs) = Mean Time Between Failures =
No.of Breakdowns

During Jan’09 ,Batching plant has run for 250 hrs.It was breakdown
for 10 times during this month.
What is the Reliability ?
250
Reliability = =25 hrs 10
 Availability Vs Reliability
Shift Hour/Planned Hours = 100 Hrs
Hours Run= 95 Hrs
Break down Detail
Day-1 = 30 min+15 min =45min
Day-3 = 45 min +15 min = 1 hr
Day-4 = 15 min
Availability Reliability Day-6 = 15 Min + 45 min =1 hr

Shift Hours = Hours Run= 95 Day-7 = 30 min

100 hrs Day-8 = 30 min
Break down =5 Stoppages= 10 Day-10 = 1 Hr
hrs
Total Break down = 5 Hrs
Available MTBF = 95/10 ~
Hours/Shift Hours 10 Availability Vs Reliability- Avly.
= 95/100=95% Failure in every is measure of duration of downtime
where as Reliability is the measure
available 10 hrs !!! of frequency of downtime.
 Asset Turn Over
Month Sales(Cr) AV(Cr)
1 100 100
2 50 105
ATO = Sales
3 75 110
Avg.AV
4 25 140
5 150 140
6 300 140
7 200 160
8 25 160 ATO = 1500/150 =10
9 150 165
10 100 180
11 50 195
12 275 200
1500 Cr 150Cr
 Productivity

(A) Output Plant

Time taken Productivit
In other words, it is “Rate of Production” y
e.g. 25 m3/hr in a CP30 batching plant

(B) Actual Production Plant

Target Production Productivit
This is used in “Process Plants” y
e.g. 6000 m3 concrete planned for Dec’09-
Actual achieved= 4000 m3
Plant Productivity = 66%
Way ahead….
 Overall Equipment Effectiveness(OEE)
OEE
• It is a severe measure of total machine performance, showing the
overall picture of where time is lost
• It categorizes time losses for the purpose of improvement
Formula

OEE = A x PE x Q
A - Availability of the machine

PE - Performance Efficiency. It is given by RE X SE.

Rate efficiency (RE) : Actual average cycle time is slower than design cycle
time because of jams, etc. Output is reduced because of jams
Speed efficiency (SE) : Actual cycle time is slower than design cycle time
machine output is reduced because it is running at reduced speed.

Q - Refers to quality rate. Which is percentage of good parts out of total

produced sometimes called “yield”.
6 BIG LOSS OF OEE?

“Traditional efficiency measure captures

only part of time losses”

Reduce
Reduce
Changeover
Changeover Breakdown
Breakdown d
d
Speed
Speed

Micro
Micro Quality
Quality
Spoilage
Spoilage
Stops
Stops Defects
Defects

10

Other time losses captured in OEE

OEE Pilot study

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