Tracesoft OEE (Downtime Analysis)

OEE: Overall Equipment Effectiveness

How would you like to know exactly which tasks within your whole operation were causing the downtime in production. Visibility of this is incredibly difficult without a system such as this. Even if a section is being monitored, collating the information into a meaningful set of data will be a timely excersise. Let the Tracesoft Downtime Recording procedures allow your operatives to collect this data quickly and easily. Reports can then show immediately where your downtime is and, more importantly, what is causing it.

In our experience many processing plants are aware that there are issues causing downtime. However, it is always difficult for the reasons to be singularly identified to the site management or engineers. with the Tracesoft system in place, procedures can be quickly developed and deployed to capture purely the information needed; Line No., Stop time, Reason, Start time.

Once this data is available a chart can instantly display the amount of production time being lost due to those reasons selected.

OEE Downtime Analysis Chart

Armed with this information, focus can be placed on each element to determine the root cause and fix the problem.

Major Benefits

- Reduction in Production Downtime
- Maximize Labour
- Increased production throughput
- Reduce scrapped product
- Communicate problem areas quickly
- Spot Trends in faulty machinery/processes
- Scaleable from single unit to multiple unit operation
- Promotes Lean Manufacturing initiates & Right First Time culture

Cost Savings on Downtime Analysis

Analysing how long a machine is inoperative is crucial to understanding what is causing the downtime. This information can then be used to
focus on those areas to improve efficiency rates for production lines.

Click the image below to view a larger version in a new window.
Download this Excel file here

Tracesoft Downtime Savings

The analysis above shows a simplified typical breakdown of a few production lines and the throughput figures. There are thousands of
products which are produced by food processors but here you can see a commonly produced item as an example.

The Throughput Per Hour and Average Daily Hours assume that the machines are running at 100% efficiency.

Throughput Per Day is then calculated from the two previous figures.

The Average Cost Per Day is a figure which is typical of this kind of product. This figure includes the production cost,
overheads and labour. This then gives us a Cost Per Hour and a Cost Per Day.

The Typical Downtime % in the first table allows operators to enter a value which is representative of how much time as a percentage
of the total daily hours is taken up with non operational machines. The Typical Downtime Per Day (Mins) is then calculated from this.

We can then work out what the value of this loss is in the Downtime Loss Per Day ($) column.

Days Per Week represents how many days the plant usually operates in any given week.

We can then claculate the Downtime Loss Per Week and Downtime Loss Per Year.

The last three columns allow us to factor in the margin which was included in the Average Cost/Kg. This is expressed as a
percentage and a monetary value which leads us to the last figure, namely the Net Downtime Loss Per Year.

The second table allows us to suggest that if the system is used, and measures are taken on problem areas highlighted by the
system, what percentage of the original downtime could be saved.

The third table simply subtracts the second table's values from the first to arrive at the savings which can be made.

Real Time Data.

As with the rest of the Tracesoft Data Capture System, all data can be captured in real time. This means that you can see results as soon as the procedure has been saved.

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