How to define OUTPUT (=’Products’)
To OEE Coach, everything coming out of the machine is a ‘product’. Each product can have a certain ‘quality’ which is reflected by the ‘category’ we place it in.
How does it work
When a machine is running, it is producing output. This can be either output within specification, or output out of spec that has to be scrapped, or output out of spec that can be reworked. The differences have been explained in Four categories of output: [G], [S], [SS] & [R]
Al output, regardless it’s category, is defined in the masterlist ‘products’ This list of output is used for each machine. If you are manufacturing a product using more than one machine, you will just have to assign that product in the Machine – Activity – Product (MAP) table Output to the different machines.
Over time, the master-table ‘Products’ will turn into a list containing all products produced by all machines in the factory. (The masterlist contains an option to import the products via a CSV file.)
When the machine is actually producing (the activity is type [P]) the machine manufactures products. The OEE requires the definition of each output. Just as the definition of the activities, keep things simple! Try to define 10 to 15 different Outputs or, in case of a large number of different Outputs, Output groups. In order to calculate the OEE, the minimum requirement is that all Outputs with different maximum speed (different standards) are defined. So, for example assign Outputs that are produced at the same production speed under one name (this output now represents an Output group). Assign a [G] for good Output to the defined output(group)s.
If a bottling machine fills 0,33 cl bottles with 20 different soft drinks, it is not necessary to look at each individual product. It is not important what goes into each bottle, but at what speed. When three different sized bottles are used, e.g. a ½ liter bottle, 1 liter bottle, and a 1½ liter bottle, each one has its own Standard. In this case consider not to define 20 different products, but just defining three ‘Output groups’.
Defining Scrap and Rework
In addition to the [G]ood types of output, the [S]crap and [R]ework products need to be defined separately.
Example: For a machine filling bottles with fruit juices two ‘Products’ that serve as ‘Output groups’ have been defined: ‘0,33 liter bottles’ and ‘0,5 liter bottles’. Besides producing good bottles (output category [G]), it can also produce broken bottles, bottles with curly labels, or bottles with loose caps.
You will have to define these quality losses as a type of Output of category [S]crap or [R]ework.
- Define general output categories for [S]crap and [R]ework.
Example: ‘Broken Bottle [S]’ , ‘Curly Label [R]’, ‘Loose Cap [R]’
- Record these quality losses whenever they occur together with the corresponding [G]ood Product. It is not necessary to make a scrap or rework product for each good product:
Example: ’0,33 liter bottle Broken’ [S] and ‘0,5 liter bottles broken’ [S]
Example: Quality losses occur in four different bottles. Therefore, besides the four good products, the following other ‘products’ have been defined: ‘broken bottle’ and ‘sharp edge’ assigned as [S]crap, ‘loose cap’ and ‘curly label’ assigned as [R]ework.
Define [S] and [R] just once
All defined [S]crap and [R]ework types can be used for all Output (group)s where this quality loss occurs. So, you only need to define a type of quality loss once.
Again, do not specify too many [S]crap and [R]ework categories.
Example: If color is an important reason for rejecting many of your products, create an output type with the name ‘not meeting color spec’ instead of specifying every color-problem.
Remember: Over time you will eliminate many of those problems and you would like to see whether your color problems are diminishing.