Module 14

(i) What FMECA Achieves

Measuring maintenance performance
Maintenance effectiveness
Maintenance efficiency.
Reliability analysis
MTBF
MTTR
Overall Equipment Effectiveness

1
Need for KPIs to Optimize Performance
1. Key performance indicators
(KPIs) to measure, monitor,
and analyze
2. How to benchmark the
process performance using
KPIs
3. Capturing losses and
achieving optimal
production performance.
2
Overall Equipment Effectiveness (OEE) Six Key Metrics
The six big losses in equipment or machines

Target
Minimize
Minimize
Minimize
Minimize
Zero
Zero
Minimize

3
OEE improvement is about addressing losses from both ends of
the Pareto chart rather than just focusing on the big losses.
OEE Standard and Its Calculations
Availability loss
1. Loss due to scheduled and unscheduled breaks
2. Loss due to setup, changeover process, material.
Performance
3. Reduced speed due to machine, material, people
4. Loss due to idling and minor stops
Quality loss
5. Material loss due to quality issues like rejects during
startup, improper setup,
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Availability
Availability is a ratio of time a machine is available to produce parts. “The time the
equipment is actual running versus the time it could have ideal running.”

The formula for calculating Availability is

Availability = Operating Time - Downtime X 100%
Operating Time
Example
A machine is scheduled to run for an 8 h X 60min (480 minutes) per shift,
1. The machine has 60 min of downtime.
2. Loading time = 480 min − 60 min unscheduled downtime = 420 mins

Availability = 420 min X 100% = 87.75%

480 mins
These indices determine that whereas (100 – 87.75)% = 12.25% of equipment
time
is lost due to maintenance, actual availability for production is only = 87.75 %
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 Availability
Total Operating Hours
Per day Conversion
Preventive Maintenance in minutes Calculation in minutes Availability percentage
Hrs Minutes

4 240 60 240-60- = 180 180 X 100 = 75%

240
8   100    
12   70    
24   120    

Loading Time
Preventive
Per day Conversion Maintenance in Breakdown in Calculation in minutes Availability percentage
Hrs Minutes minutes
minutes

4 240 60 30 240-60-30 = 150 150 X 100 = 62.5%

240
8   100 120    
12   70 0    
24   120 150    
 Availability
Total Operating Hours with Planned downtime
Conversion
Per day Hrs Minutes Preventive Maintenance in minutes Calculation in minutes Availability percentage

4 4 X 240 60 240-60 = 180 180 X 100 = 75%

240
8  8 X 480 100  480-100 = 380 380 X 100 = 79.2%
480
12  12 X 720 70  720-70 = 650 650 X 100 = 90.3%
720
24  24 X 1440 120  1440=120 = 650 1320 X 100 = 92%
1440

Total Operating Hours with unplanned downtime

Conversion Preventive Maintenance Breakdown in
Per day Hrs Minutes in minutes minutes Calculation in minutes Availability percentage

4 4 X 240 60 30 240-60-30 = 150 150 X 100 = 62.5%

240

8  8 X 480 100 120 480-100-120 = 260 260 X 100 = 54.2%

480
12  12 X 720 70 0 720-70 = 650 650 X 100 = 90.3%
720
24  24 X 1440 120 150 1440=120-150 = 1170 1170 X 100 = 81.3%
1440
Overall Equipment Effectiveness (OEE)
How to Improve availability:
1. Unplanned downtime.
2. Identify common causes.

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Performance (Net Operating Time )
The Performance rate is composed of the speed operating rate and the net operating
rate.
It represents the speed at which the machine runs (Actual) as a percentage of its
designed speed (Ideal) of the machine.
The formula for calculating Performance is
Performance = Actual Output X 100%
Ideal Output
Example
1. The Available Time is = 480 min scheduled − 60 min unscheduled downtime =
420 min.
2. The Ideal Rate for the part being produced is 40 Units/hour, and the machine
produces 242 Units during the shift.
3. Ideal Output 420 min/60min 7 hr X 40 = 280 units.
Performance = 242 Units X 100% = 86.4%
280 Units
These indices determine that whereas (100 – 86.4)% = 13.6 % of equipment time
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Is lost due to maintenance, actual The performance rate for production is only 86%
Overall Equipment Effectiveness (OEE)

1. Ideal cycle time.

2. Identify and close the gap
of imbalance operations

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Quality (Valuable Operating Time)
3. How many products met the specifications?
The relationship between the number of units produced and the number of the
units produced that meet the specification is the ‘quality rate’.
The formula for calculating Quality is
Quality = Good Units X 100%
Units Produced

Example
1. A machine produces 230 Good Units during a shift.
2. Total units produced 242 Units
3. Therefore, the Quality metric is Quality
Quality = 230 Good Units X 100% = 95%
242 Units
These indices determine that whereas (100 – 95)% = 5% of equipment time is
lost due to
maintenance, actual The performance rate for production is only 95%
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Overall Equipment Effectiveness (OEE)

1. Identify, measure,
and improve scrap
and rework.
2. Identify problem areas
and install error or
mistake proofing.

13
How do I calculate (OEE)?
OEE is a product of three separate but measurable components:
Availability, Performance, and Quality.
The formula for calculating OEE is
OEE = AVAILABILITY X PERFORMANCE X QUALITY
87.25% X 86.4% X 95% OEE= 71.61%
Overall Equipment Effectiveness
Bar Chart
1. OEE is an “improvement
driver.”
2. Understanding Loss of
Effectiveness
3. The Reliability Approach
4. Improving OEE on
5. Existing Machinery
14
Workshop Exercise

15
• 5 Working Days
• Three shifts of 8 hours each working day
• 30 minutes break each shift
5 days X 3 Shifts X 8 Hours = 120 Hours
15 X 30 Minutes = 450 minutes = 7.5 Hrs
60
Measurement for one week period
7 Breakdown = Totalling 21 hours
16 Set, average ½ hours each = 8 hrs
Availability = 120 Hrs – 7.5hrs – 21hrs – 8hrs = 83.5 hrs = 69.6 %
120hrs 120 hrs
Availability = 120 Hrs – 7.5hrs – 21hrs – 8hrs = 83.5 hrs = 69.6 %
120hrs 120 hrs

Performance = 83.5 Hrs X 1800 units per hour

= 150300 units

Performance = 10200 Units X 100% = 67.9%

150300 units
Availability = 120 Hrs – 7.5hrs – 21hrs – 8hrs = 83.5 hrs = 69.6 %
120hrs 120 hrs

Performance = 10200 Units X 100% = 67.9%

150300 units

Quality = 102000- 2000 = 100000 Good Units X 100% = 98 %%

102000 Total Units
 Overall Equipment Effectiveness
100.00% 98.00%
90.00%
80.00%
69.60% 67.90%
70.00%
60.00%
50.00%
40.00%
30.00%
20.00%
10.00%
0.00%
Availability Performance Quality
Responsibility and Accountability for OEE
1. Who should be responsible and
accountable
2. Identify the activities
3. To eliminate or minimize the losses.
• Detect and Predict Deterioration
• Establish Repair Methods
• Restore Deterioration
• Maintain Operating Standards
• Maintain Basic Equipment Conditions
• Prevent Incorrect Operation
• Prevent Repair Errors
• Improve Design Weaknesses
Why Preferred OEE Calculation?
In the preferred calculation you
get the best of both worlds.
A single number that captures
how well you are doing (OEE)
and three numbers that capture
the fundamental nature of your
losses

OEE is improving. Great job! Or is it?

Dig a little deeper and the picture is less clear.
Most companies would not want to increase Availability by 5.0% at the
expense of decreasing Quality by 4.5%.
A related measure is mean-time-to-repair
(MTTR), the mean time needed to repair an
instrument.
1. MTTR = Mean time to detect that a failure
occurred
2. + Mean time to troubleshoot the failure
3. + Mean time to repair the failure
4. + Mean time to get back in service
 
Mean Time Between Failures (MTBF) for Failure Analysis
MTBF is the average time between failure occurrences.
The equation would be the operating time of equipment divided by the total number
of failures.
Uptime: the moment at which a machine began operating (initially
or after a repair)
Downtime : the moment at which a machine failed after operating since the previous
uptime-moment

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Class Exercise
Calculate the MTBF
Operating Time Days
117 245 405 545 117 128 160 140
Number of Stoppages

15 15 20 25Hr 40 30Hr 35
5 Hrs
Hrs Hrs Hrs s Hrs s Hrs

Total Repair Time

Class Exercise
Calculate the MTBF

= 1857 = 232.1 days

8
Workshop Exercise
What is the MTBF of a pump that has an operating time of 500 hrs experienced,
please ignore the planned downtime No Planned Unplanned
1. Two replaced seals, 1
2. One motor replacement, 2
3. One replaced coupling, 3
4. One Planned PM meeting, 4
5. Two Planned filter cleanings 5
Perform the following appropriate calculations.

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Mean Time To Repair (MTTR)
1. The measure of the ability of an item to be restored to a specified
condition when maintenance is performed by personnel having
specified skill levels, using prescribed procedures and resources, at
each prescribed level of maintenance and repair.
2. Maintainability is most commonly measured by mean time to
repair(MTTR)

“If it ain’t broke, don’t fix it” the paradigm of thoughts need to change 28
Class Exercise
Calculate the MTBF
Operating Time Days
117 245 405 545 117 128 160 140
Number of Stoppages

15 15 20 25Hr 40 30Hr 35
5 Hrs
Hrs Hrs Hrs s Hrs s Hrs

Total Repair Time

Class Exercise
Calculate the MTTR

= 185 = 23.1 Hrs.

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Module Summary
1. Learning take place by sharing
2. Contents relevant to your Job
3. Can you utilize the learning to your
workplace
4. Clarification of the objectives
5. Any of your questions doubts
answered
6. Outcome of the team activities helpful
7. Is the content understandable
8. Training exposed to new knowledge
MTBF (or reliability) and
MTTR (or maintainability)
are the parameters that
influence and simplify the
job considerably.
 RCM is a
Continuous Improving
Living program not a
destination it is a
Journey 33