OEE Improvement project

Team of the project

1. Eng. Ehab Abo Elkhier

2. Eng. Ahmed Shawky

3. Eng. Mohamed Ramadan

4. Eng. Hamdy Saber

5. Mahmoud khairy
Pareto chart for unplanned breakdowns
 To improve OEE we considered the largest 4 unplanned
breakdown

This 4 break downs represents 58.35% of all unplanned break downs

1. Lack of workers number. (21.33%)
2. C.T difference. (17.72%)
3. Die and pin breakdowns. (10.05%)
4. Adjusting neck thickness and height ( cutting bushing ). (9.24%)
Root Cause analysis
Lack of
1. Lack of workers number workers

Actual head Stoppages due Quarantine

required higher to workers due to Covid
than planned head absence 19

Deflash During farming

mechanism Products need seasons (June)
breakdown more workers
than planned

Efficiency
decreases

Damaging the Increase

Product Fail
product neck and Machine
in drop test
body breakdowns
 Lack of workers due to farming seasons

Absent Monthly Absent Monthly Percentage of Absent Monthly Percentage of

BD Percentage of Absent workers BD BD
workers total BD workers total BD Absent workers workers total BD Absent workers

May-17 683.58 8966.8 7.62% Jan-19 197.33 7928.92 2.49% Jan-20 48.92 3337.08 1.47%

Jun-17 1006.25 7744.58 12.99% Feb-19 109.67 7318.92 1.50% Feb-20 92.83 3611.08 2.57%

May-18 442.92 8152.61 5.43% Mar-19 112.08 8325.67 1.35% Mar-20 784.67 4463.98 17.58%

Jun-18 1004.92 6768.5 14.85% Apr-19 59.167 7795.25 0.76% Apr-20 1037.67 4204.58 24.68%

May-19 2049 10874.33 18.84% May-19 2049 10874.33 18.84% May-20 520 4240.5 12.26%

Jun-19 2741.83 10463.83 26.20% Jun-19 2741.83 10463.83 26.20% Jun-20 1410.75 5681.4 24.83%

Lack of workers due to products needs Due to covid-19

Product No of workforce increase Machine Production section

1 liter Clorel 1 23 5 liter C

1 liter Clorel 1 25 5 liter C

1 liter Velveta 1 5 5 liter A

330 milliliter Velveta 1 5 5 liter A

Rabido 1 8 5 liter B
 2. C.T Difference

C.T
Difference

Small
No parison control dimensions Neck Surface Deformation
Deformation
Cooling paths Operating Raw
Machine clogging conditions material Unbalanced
and Excessive Cooling material
4 5LT change
master Cooling reinforcement paths distribution
Metal
Presence of Air Cooling Cooling batches paths under neck clogging
corrosion
Contaminated pressure water water different clogging Die
and rust Load
salts pressure temperatur deformation
Leakage in e test
connectors Compressor
Machine 4/5
breakdown Pump Sheller Client
20LT
breakdown breakdown requirement

Machine
22/24 5LT
3- Die and pin breakdowns

Surface
defects

Surface Thermal Weakness

Roughness lines lines

Improper
mix Contaminat
Material Improper mix Heaters over between
heating ed regrind
build up between regrind and
regrind & raw raw material
material
Too much
Heaters Presence of Cutting
Machine handling for
under bad material edges wear
stoppages regrind
heating
Long Low
No filters in distance
Low Low work preventive
Heater Wrong the between
Air leakages training instructions maintenance
breakdown setting machines machine for crushers
and
crushers
4- Adjusting neck thickness and height ( cutting bushing ).

Adjusting neck thickness and height

( change cutting edges).

Problem in blow-pin Low training for

Cutting edges wear
parts technicians

Wrong Blow-pin
material pressure Broken pins
selection increase

Low Low life Low skill No checking

cost time
worker procedure for
blow-pin pins

Low
training
 Machine 17 Section 5L A
Ra
Die He Uns No Scr
and at Die andwpin Adjustment
tabl
out
mat e ew
pin line eria neck put
&
adj s in l and me
Ba
Die Ov
ust pro usa bott asu
me duc Heatge om
rem
Pro
rre
and mat
blel
nt t linesy
onl
erial
erh ent
pin
in m in
adju
stme prod eat heat
nt ucts
Action: Eng. Ahmed Abdelkhalik will investigate the
ing ers
problem with Maintenance Department
Machine 21 Section 5L C

Die and pin adjustment

Die Heat und Probl
and lines
erhe em in
pin in
adjust atin heate
produ
ment cts g rs
Action: Calibration for heaters done and found the problem in
the heater number 8 and change the heater

Problem is still unsolved need another

action
Machine 26 Section 5L B

Die and pin adjustment

Die Heat Colo
High
and lines percen
red tage of
pin in pigam
adjust produ dye
ents in
ment cts burnt dye
Action: search for new supplier for a better masterbatch
Machine 7 Section 5L B

Die and pin adjustment

Die Heat High
lines in
and pin heaters
Metallic
adjust colours temper
ment in mobile atures
Action:
1. recommend use ceramic die and pin with standard profile
2. search for new supplier for a better masterbatch
3. Remove the machine head and clean it between colours
changeover but this solution will take time
Machine 4 Section 5L A

Cycle time difference

Non uniform
Cycle time No parison
material
difference control
disturbtion

Action: Parison control to be made for the machine and

machine restoring required

Problem is successfully solved

Machine 5,4 Section 20L

Cycle
Necktime difference Proble
Not
Cycl m in
dime effect
e water
nsion ive
time coolin
s Cooli g
differ
probl ng syste
ence water
em m
Action: cleaning the cooling pipes in the die and increasing the holes of water manifolds
Machine 23,25,27 Section 5L C

Neck Neck thickness

Neckand height adjustment Hardne
thickn dime
Bad ss of
cutting
ess
and
nsion Cut tip
s materia
height ting l not
adjust probl
ment em tip suitabl
e

Action: Use cutting tip of material K 110 Steel with good heat
treatment process
Machine 7 Section 5L B

Neck thickness and height adjustment

Neck
Material of
thickness and Wear in the cutting tip
height cutting tip
adjustment
is not suitable

Actions
1. Use cutting tip of material K 110 Steel with good heat
treatment process
 Actions implementations and results
Before hardening cutting tool After hardening cutting tool
material K110 material K110
Percentage of the Unplanned Total Unplanned Percentage of the Unplanned Total Unplanned
breakdown from breakdowns hours working breakdowns breakdown from breakdowns hours working breakdowns
working hours hours working hours hours

1.8% 967 52950 ‫فونيه و دكر‬ 1.6% 3407 210241 ‫فونيه و دكر‬

1.4% 724 ‫تغيير جلبة‬ 1.8% 3804 ‫تغيير جلبة‬

0.7% 388 ‫دورة تشغيل‬ 2.7% 5665 ‫دورة تشغيل‬

0.9% 503 ‫عماله‬ 2.8% 5932 ‫عماله‬

Jan 2020 until Nov 2020 Dec 2020 until 25th of Feb 2021
 Cutting tool Change
(unplanned breakdown )
Before After
Cutting tool change
Cutting tool change
4.5% 3.0%
4.0%
2.5%
3.5%
3.0% 2.0%
2.5%
1.5%
2.0%
1.5% 1.0%

1.0% 0.5%
0.5%
0.0%
0.0% 7 \‫م\اك\ينة‬ 9 \‫م\اك\ينة‬ 23 \‫م\ا\ك\ينة‬ 25 \‫م\ا\ك\ينة‬ 27 \‫م\ا\ك\ينة‬
7 ‫ما\كينة‬ 9 ‫ما\كينة‬ 23 ‫ما\كينة‬ 25 ‫ما\كينة‬ 27 ‫ما\كينة‬
 Die and pin adjustment
(unplanned breakdown )
Before After
Chart Title
Die and pin adjustment Die and pin adjustment
4.0% 6.0%
3.7%

3.5% 5.2%
5.0%
2.9%
3.0%
2.6%
2.6%
2.5% 4.0%
2.5%
3.3%
2.0% 3.0% 2.7%
2.3%
1.5%
2.0%
1.0% 1.4%

1.0%
0.5%

0.0% 7 \‫م\ا\ك\ينة‬ 9 \‫م\اك\ينة‬ 17 \‫م\اك\ينة‬ 21 \‫م\ا\ك\ينة‬ 26 \‫م\اك\ينة‬ 0.0%

7 ‫م\اك\ينة‬ 9 ‫م\اك\ينة‬ 17 ‫م\اك\ينة‬ 21 ‫م\اك\ينة‬ 26 ‫م\اك\ينة‬
 OEE results

Before After
Chart Title
Avaliability trendline
84.0%

82.0%

80.0%

78.0%

76.0%
Decreasing trend
74.0%

72.0%

70.0%

68.0%

66.0%
43831 43862 43891 43922 43952 43983 44013 44044 44075 44105 44136 44166