How Can You Use Root Cause Analysis to Improve Overall Equipment Effectiveness (OEE)
Before we explain how root cause analysis can improve overall equipment effectiveness (OEE), let’s look at the basics of OEE.
OEE is a measure of how efficiently you are using your equipment to produce your product after subtracting scheduled losses. Scheduled losses include:
- scheduled plant shutdowns or maintenance time,
- scheduled breaks, lunches, holidays, or weekends,
- shutdowns due to no need for production (no orders).
OEE is different that Total Effective Equipment Performance (TEEP). OEE should be a higher percentage than TEEP.
TEEP baseline is 7 days per week and 24 hours per day. OEE starts with planned production time which is TEEP’s baseline minus the time lost due to the items in the list above (scheduled losses).
Losses are subtracted from Planned Production Time to give you the measure of Fully Productive Time.
Fully Productive Time considers these losses that are subtracted from Planned Productive Time:
- Availability Loss: Time lost due to stopped production including equipment failures, material shortages, and change over time.
- Performance Loss: Loss production due to running the equipment at less than the full rated speed. For example, running the equipment slower to produce the needed quality, a quick stop to make adjustments to maintain quality or equipment performance, or misfeed, jams, or quickly replacing warn equipment.
- Quality Loss: The losses due to manufactured parts that do not meet required standards (quality requirements of the customer). This includes scrap or rework.
Here is an article that explains OEE calculations in more detail:
Calculating these losses and arriving at the number for TEEP and OEE is called a Loss Analysis and is explained in more detail in this video…
That should give you ideas about calculating OEE and TEEP. But what does that have to do with root cause analysis?
To improve OEE, your measure of effectiveness when using your equipment, you need to reduce Availability Loss, Performance Loss, and Quality Loss. When any of these losses occur, you have an OEE incident.
For example, if the equipment failed and required unscheduled maintenance, you would need to troubleshoot the failure and you could perform a root cause analysis of the equipment failure.
Equifactor® was designed to troubleshoot equipment failures. It has a standard list of equipment troubleshooting tables or you can develop your own custom troubleshooting table for your specific equipment and add them to the existing Equifactor® Troubleshooting Tables.
Once you know how the equipment failed and if you decide that the failure is significant enough to require a root cause analysis, you can perform the root cause analysis using the TapRooT® System.
The TapRooT® System has you draw a SnapCharT® Diagram to help you understand what happened (including the information gained using the Equifactor® Troubleshooting Tables), and use the Root Cause Tree® to help you identify the root causes of human performance or equipment failure Causal Factors.
Finding and fixing the root causes or OEE incidents is how TapRooT® Root Cause Analysis can help you improve Overall Equipment Effectiveness to improve your plant’s production performance and profitability.
Six Ways to Learn More About Equifactor® Troubleshooting and TapRooT® Root Cause Analysis
First, there are several articles you could read to learn more about Equifactor® Troubleshooting and TapRooT® Root Cause Analysis, including…
- Equipment Failure? Use Equifactor® Troubleshooting During Your Root Cause Analysis
- Equifactor® Equipment Troubleshooting Basics
- Ensure your equipment failures are fixed the FIRST time with Equifactor®
Visit the home page for Equifactor® Troubleshooting (CLICK HERE).
Second, you can watch this video about Equifactor® Troubleshooting and TapRooT® Root Cause Analysis…
4. Equifactor® Book
Third, you can read Book 5: Using Equifactor® Troubleshooting Tools & TapRooT® Root Cause Analysis to Improve Equipment Reliability.
To order the book, see:
Fourth, you can attend the FREE 90-minute On-Line Equifactor® Equipment Troubleshooting Webinar on October 7th:
6. In-Person or Virtual Training
Finally, you can choose to attend one of our courses:
They both courses cover the same topics. One is in-person and one is live, but virtual (no travel required). They both include Book 5: Using Equifactor® Troubleshooting Tools & TapRooT® Root Cause Analysis to Improve Equipment Reliability as part of the course materials.
The next 2-Day Equifactor® Equipment Troubleshooting & TapRooT® Root Cause Analysis Course is in Houston, TX, on November 3, 2021.
The next VIRTUAL Equifactor®/TapRooT® Training is November 15 starting at 10 AM EST.
No matter which course you choose, we guarantee it will help you perform systematic equipment troubleshooting and find the true root causes of your equipment problems that you previously would have overlooked. Plus it will help you develop corrective actions that you and your managers will agree are much more effective.
Don’t wait! GET REGISTERED for Equifactor® Training TODAY!