Overall equipment effectiveness system

Abstract

Modern manufacturing equipment has become highly automated and sophisticated. High levels of output can now be achieved, hence the need to monitor the production process. The greatest hindrance to achieve higher output are the six big losses to production. The six big losses are start-up rejects, production rejects, small stops, setup and adjustment, equipment failure and slow cycles. In order to counteract these losses it is necessary to monitor machinery performance through the calculation of overall equipment effectiveness (OEE). In this regard Mega Pak Zimbabwe employed a manual system to track and monitor OEE. The process was tedious and consumed a lot bond paper. The main object of this project is the creation of a computerised system to efficiently monitor, trend and evaluate OEE at Mega Pak Zimbabwe. It also seeks to compare target OEE against actual OEE and notify the plant manager when OEE has decreased below target. Questionnaires, interviews and observations were used to gather information on how OEE was being monitored. It was noted that employees complained that the process of calculating OEE was time consuming and prone of errors resulting in misleading results. Development tools used include MySQL, Apache, PHP and Sublime text editor. Based on gathered information a feasibility study was conducted to assess the economic, technical and social viability of the project. In-house development was selected as the most appropriate development strategy given the prevailing economic situation. Multiple tests including acceptance test, integration test and performance test were conducted on the system to ensure that it meets user requirements and is free of bugs. To prevent confusion regarding the use of the new system a pilot changeover strategy was employed. This gave employees enough time to adjust to the demands of the new system. Employees were trained on how to use the different functions they had access to such as adding new production details and customising reports. Maintenance of the system will be an ongoing process in order to carry out planned maintenance and incorporate new user requirements. For future development it was recommended that the system be integrated with electronic dashboards or televisions in the production area to give shifts a visual appreciation of their work rate. An effective OEE system will among other thing help Mega Pak Zimbabwe to maintain their position as the leading plastic manufacturing company in Zimbabwe.