From wikipedia, the free encyclopedia overall equipment effectiveness oee is a term coined by seiichi nakajima in the 1960s to evaluate how effectively a manufacturing operation is utilized. Oee s origin was actually human before it was machine. Introduction to total productive maintenance by seiichi nakajima. He established the pm awards currently the tpm awards.
It is based on the harrington emerson way of thinking regarding labor efficiency. Oee overall equipment effectiveness blom consultancy. The idea of oee is not a new oneit came about back in the 1960s, pioneered by seiichi nakajima. The first application of oee can be traced to the late 1960s when it was used by seiichi nakajima at nippon denso as a key metric in tpm total productive maintenance. Aug 09, 2019 the total productive maintenance definition is where the manufacturing process and equipment maintenance are combined. Improving oee metrics with microsoft dynamics and power bi.
The principles of oee were deployed by seiichi nakajima in 1982. Total productive maintenance tpm was developed by seiichi nakajima based on the experience of the practical application of maintenance best practices in japan between 1950 and 1970. The advantage of an integrated approach is that the oee system. How to optimize overall equipment effectiveness with iot. Cayman systems usa 5 7773394 1998 revision a 980810 tpm awareness information 3 courtesy, in part, of motorola sps. He characterized maintenance as the responsibility of all employees. Calculating overall equipment effectiveness oee graphic. Oee or overall equipment effectiveness to give it its full title is a tool within the tpm total productive maintenance method. First popularized in the 1960s by seiichi nakajima, founder of the total productive maintenance system, oee is a function of a units availability, performance compared to designed capacity and product quality. You want to apply oee on a production line but you also need to measure the weight of the products every 20 minutes. Pdf analysis of overall equipment effectiveness oee. Leveraging real time data for assessing process plant oee. And this book, this book can make that vision better and better found on by carlos soto knowledge eater medellin, colombia. Overall equipment effectiveness oee fullfact solutions.
Seiichi nakajima the father of oee and total productive maintenance methodology effectively captured these inefficiencies in his six big losses framework. Total productive maintenance tpm and overall equipment. Total productive maintenance tpm is an approach to equipment maintenance that aims to achieve a perfect production process by increasing productivity, efficiency, and safety. Overall equipment effectiveness oee is a widely us ed performance indic ator i n manuf acturing industries around the world. At the end of the chapter, industrial examples of oee application are presented and the results are discussed. Oee software provides the final grading along with keys to unlock the.
Overall equipment effectiveness oee is a hierarchy of metrics developed by seiichi nakajima in the 1960s to evaluate how effectively a manufacturing operation is utilized. Overall equipment efficiency oee has been a core principle of manufacturing management since its invention in the 1960s by seiichi nakajima. Nakajima, seiichi, introduction to total productive maintenance, 1984 japan, 1988 productivity press, out of print. Tpm can be defined in terms of overall equipment effectiveness oee, which in turn can be considered a combination of the operation maintenance, equipment management, and available resources. He is commonly referred to as the father of tpm and he stated that continuous improvement of oee is one of the main goals of tpm total productive maintenance. Nakajima was unsatisfied with the traditional models used to calculate efficiency and he set out to develop oee, a model that would not be so easy to manipulate. Oee served as a key metric in tpm total productive maintenance. Total productive maintenance preventative maintenance series hardcover october, 1988 by seiichi nakajima author, norman bodek introduction 2.
Sep 24, 2018 seiichi nakajima, the originator of total productive maintenance in the 1960s, created the technique for evaluating the manufacturing system. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. The goal of tpm is to maximize equipment effectiveness, and the oee is used as a measure waeyenbergh and pintelon 2002. This feature is unique and makes oee a vital element of all serious improvement strategies for manufacturingprocesses, including tpm. Tpm was described by nakajima as a plant improvement methodology, which enables continuous and rapid improvement of the manufacturing process through the use of employee. How to achieve worldclass oee in all your factories. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of. Seiichi nakajima developed tpm and the six big losses in 1971 while at the japanese institute of plant maintenance. Seiichi nakajima, the orginator of oee and tpm, and the six big losses, thought up this number 30 years ago, way back in 1984. Total productive maintenance tpm was developed by seiichi nakajima based on experience of the practical application of maintenance best practice in japan between 1950 and 1970. Seiichi nakajima, destijds werkzaam binnen het eerdergenoemde jipm. Specifically, the goal of tpm as set out by seiichi nakajima is the continuous improvement of oee by engaging all those that impact on it in small group activities. Find all the books, read about the author, and more. Dec 05, 2016 overall equipment effectiveness oee is a term coined by seiichi nakajima in the 1960s to evaluate how effectively a manufacturing operation is utilized.
The concept of oee was developed as a metric and tool to be used for improving operating efficiency of manufacturing plants. Seiichi nakajima published a book in 1984 called tpm nyumon published in english as introduction to tpm. In his book introduction to tpm published in 1988, he notes that prizewinning companies have oee scores of 85% or moreknown as the world class rating. Development of tpm is attributed to seiichi nakajima of the japan institute of plant maintenance jipm in japan in the 1960s and 1970s.
Overall equipment effectiveness oee is a measure of how well a manufacturing operation is. It is the ratio between the theoretical maximum capacity vs the actual output. In other words, oee is the percentage of manufacturing time that is truly productive. The idea of total productive maintenance was first developed in the 1950s by seiichi nakajima, although the phrase wasnt widely used until years later. Today, oee is a globally accepted standard for measuring productivity. Oee is a productivity metric that represents the ratio between actual good output and theoretical good output. While data was once collected manually and typically focused on a single piece of equipment, more modern oee calculations factor in the output of various. Total productive maintenance, which we highly recommend as an introduction. Seiichi nakajima author visit amazons seiichi nakajima page. The oee industry standard provides guidelines to define oee in the best possible way to visualize all losses on your equipment. The term oee was first used by japanese maintenance consultant and teacher seiichi nakajima in the 1960s.
Manufacturing companies typically operate around 60 to 65 percent oee. The six big losses are well aligned with the three core elements of oee mentioned above. An oee of 100% means that only good parts are produced 100% quality, at the maximum speed 100%. Overall equipment effectiveness oee is a tool used to evaluate how well a manufacturing process is functioning. The oee calculation is based on pioneering work by seiichi nakajima in the field of tpm in the early 1970s while at the japanese institute of plant maintenance. T otal productive maintenance tpm was first developed in 1969 in japan at nippon denso co. Total productive maintenance preventative maintenance series english and japanese edition seiichi nakajima, norman bodek on. Pioneers in overall equipment effectiveness our oee toolkit was the very first enterprise oeesuite ever 1996, developed by fullfacts team. Overall equipment effectiveness oee was conceptualized and introduced by the father of total productive maintenance tpm, seiichi nakajima. Aug 03, 2016 the term oee, or overall equipment effectiveness was introduced by seiichi nakajima at nippon denso. To achieve this, the tpm toolbox sets out a focused improvement tactic to reduce each of the six types of oee loss. A managers guide to overall equipment effectiveness oee. Seiichi nakajima gave that vision by his oee s ideas.
The term oee, or overall equipment effectiveness was introduced by seiichi nakajima at nippon denso. Tpm total productive maintenance 8 tpm pillars lean tool. Total productive maintenance is introduced in 1971 by japans jipm. Overall equipment effectiveness has been around a very long time, since the 1960s. Frequently asked questions about lean lean production faq. Total productive maintenance, which we highly recommend as an as an excellent and practical introduction to tpm, oee and the six big losses. Overall equipment effectiveness from where and when did oee originate. Oee was first described as a central component of the tpm methodology in seiichi nakajimas book tpm tenkai 1982, jipm. It contains three minor metrics, which are availability, performance and quality. Oee is expressed as a percentage from 0 to 100, where an oee score of a 100 percent would equal the manufacturing unit operating at full capacity. The six big losses originate from the world of total productive maintenance tpm. A lean manufacturing term developed by the japanese, specifically seiichi nakajima oee establishes routine in determining how effective each operation step in manufacturing is. It is initiated when nakajima introduced the total productive.
As a pioneer we know the needs of operators, mechanics, team leaders and operations managers. The origin of oee seiichi nakajima japan oee was first described as a central component of the tpm methodology in seiichi nakajimas book tpm tenkai 1982, jipm tokyo. Oee is most effectively applied in production where units are produced or created, such as capsules, vials, bottles, syringes, intravenous iv bags and packaging blister packs, cartons. Next happy hour, drink a toast to bugsy siegel and of course to seiichi nakajima. Proven strategies and techniques to keep equipment running at maximum efficiency mechanical engineering 1st edition by steve borris. It is based on availability, performance and quality numbers of 90 %, 95 % and 99 % respectively. It is still recognized as a key metric in total productive maintenance tpm and lean production programs, but the manufacturing sector has changed a lot since the 60s.
By the end of the 1980s, the concept of tpm became more widely known in the western world. Total productive maintenance is introduced in 1971 by japans jipm oee foundation. Seiichi nakajima 1919april 11, 2015 was a japanese citizen and pioneering founder of the total productive maintenance system. The process oee includes three important goals, and the basic premise is to calculate an operating efficiency. In his 1984 book, introduction to tpm translated to english and published in 1988 by productivity press, seiichi nakajima included the above four worldclass numbers. Implementing total productive maintenance seiichi nakajima on. This was translated from the japanese book tpm tenkai published in 1982.
It identifies the percentage of manufacturing time that is truly productive. Oee is a really powerful tool that can be used also to perform diagnostics as well as. Oee is a universally accepted set of metrics, used by manufacturing entities. Total productive maintenance preventative maintenance series english and japanese edition. Jan 06, 2020 total productive maintenance tpm is a highlevel maintenance philosophy that has spawned much research and analysis from academics. This was the first book in english on total productive maintenance tpm a system which has been shown to reduce breakdowns to almost zero and increase worker productivity by as much as 150 percent. Oee also wants to know where the differences, so the losses, can be found. Nakajima for building the foundation for what should be the most strategically important equipmentmaintenance approach today and well into the foreseeable future. A concise guide to oee software in the age of smart manufacturing. Tpm was further developed and refined in japan during the following decade, and reached america in the mid1980s. Apr 08, 2020 first popularized in the 1960s by seiichi nakajima, founder of the total productive maintenance system, oee is a function of a units availability, performance compared to designed capacity and product quality. The three goals of tpm are zero unplanned failures, zero product defects, and zero accidents.
Seiichi based oee off of harrington emersons idealisms on labor efficiency. Improving the manufacturing plant can goes nowhere if you go blind. Total productive maintenance is a continuous improvement program. Fundamentals of oee overall equipment efficiency or effectiveness oee is a hierarchy of metrics proposed by seiichi nakajima 3 to measure the performance of the equipment in a factory. It is still recognized as a key metric in total productive maintenance tpm and lean production programs, but the manufacturing sector has changed a. Overall equipment effectiveness is the calculation made by seiichi nakajima in the 1960s to assess how efficient production equipment is used and to demonstrate the effects of the tpm total productive maintenance method. Jun 06, 2019 the term oee was first used by japanese maintenance consultant and teacher seiichi nakajima in the 1960s. It works to prevent problems from occurring, instead of responding to problems. The concept has been introduced by seiichi nakajima to evaluate and compare machine effectiveness and is calculated by the formula. Therefore, the oee calculation poses three questions. Jun 02, 2014 the concept of overall equipment effectiveness was first written about in 1989 from a book called tpm development program implementing total productive maintenance, edited by seiichi nakajima from the japan institute of plant maintenance.
The term oee was coined by seiichi nakajima, one of the pioneers of the total productive maintenance system. Seiichi nakajima of the japan institute of plant maintenance jipm, tokyo. Calculating overall equipment effectiveness oee graphic products. Overall equipment effectiveness oee is part of the process in improving manufacturing efficiency. Tpm was described by nakajima as a plant improvement methodology, which enables continuous and rapid improvement of the manufacturing process through the use of employee involvement, employee empowerment and. Conduct asset performance management with a softwarebased. Seiichi nakajima to measure the performance of the equipment in a factory. Overall equipment effectiveness oee is a term coined by seiichi nakajima in the 1960s to evaluate how effectively a manufacturing operation is utilized. Nakajima, a japanese engineer, served as an interpreter for presentations on preventive maintenance given by american george smith, someone at the forefront of maintenance improvement. Oee 1982 stands for overall equipment effectiveness. Seiichi nakajima first introduced the concept of oee in the early 1980s in a book published by the japan institute of plant maintenance. Oee overall equipment effectiveness or overall equipment. Understanding oee helps improve productivity, work flow and profitability.
In his 1984 book, introduction to tpm translated to english and published in 1988 by productivity press, seiichi nakajima. The concept of overall equipment effectiveness was first written about in 1989 from a book called tpm development program implementing total productive maintenance, edited by seiichi nakajima from the japan institute of plant maintenance. Total time nonavailability due to maintenance, repairs etc. The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. Advantages integrating spc and oee in most production situations you have a combination of oee and spc requirements.
Nakajima was honored by the emperor of japan with the ranju hosho, or medal with blue ribbon. The award recognizes individuals with significant lifetime achievements, and was given to nakajima. The definition of oee overall equipment effectiveness. The tpm system was developed by seiichi nakajima of. The total productive maintenance definition is where the manufacturing process and equipment maintenance are combined. Cayman systems usa 5 7773394 1998 revision a 980810. Worldclass oee set oee targets to drive improvement oee. Overall equipment effectiveness oee is a measure of how well a manufacturing operation is utilized facilities, time and material compared to its full potential, during the periods when it is scheduled to run. Maintenance and reliability workers are always striving for perfect.
While oee is an excellent calculation to benchmark productivity, it needs to be redefined for the modern era. A lean manufacturing term developed by the japanese, specifically seiichi nakajimaoee establishes routine in determining how effective each operation step in manufacturing is. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of effective. The term oee has been around for over 50 years, created by seiichi nakajima, a japanese citizen and pioneer of the total productive maintenance system. This way, attributed causes of low oee can be transparent to maintenance, operations and management. History of overall equipment effectiveness seeking to find a better, more accurate way to calculate efficiency in manufacturing and see where and why loss is occurring, seiichi nakajima invented oee by figuring the maximum rate a machine could theoretically produce, and weighing it against the number of units it actually produces. Calculating overall equipment effectiveness oee using automated. A lean manufacturing term developed by the japanese, specifically seiichi nakajimaoee establishes routine in determining how effective each operation step. Oee oee or overall equipment effectiveness to give it its full title is a tool within the tpm total productive maintenance method. Its origins come from the framework of total production maintenance tpm, introduced by seiichi nakajima s introduction to total. The term oee was invented in the 1960s by the japanese pioneer and creator of the total productive maintenance system, seiichi nakajima. Seiichi nakajima led the introduction of tpm, oee and the six big losses in the early 1970s while at the japanese institute of plant maintenance. Seiichi nakajima, the originator of total productive maintenance in the 1960s, created the technique for evaluating the manufacturing system. May 08, 2017 improving oee overall equipment effectiveness.
Total productive maintenance was developed by seiichi nakajima in japan between 1950 and 1970. Oee has come a long way since it was first introduced by japanese manufacturing industry pioneer seiichi nakajima in the 1960s, as a means to assess manufacturing operation effectiveness. The results are stated in a generic form which allows comparison between manufacturing units in differing industries. Oee is a measure of how well a manufacturing operation is used, compared to its full potential. Instead of doing a deep dive into all the tools, techniques, and methodologies involved in tpm, our goal is to introduce the main ideas of total productive maintenance in a simple, straightforward way. Oee was first described as a central component of the tpm methodology seiichi nakajima. Oee overall equipment effectiveness a practical guide.
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