Apr 12, 2023 www.leanteamsusa.com 1

Robert BairdLean Teams USA

+1 215 353 0696

Design For OEE (DFOEE)

Apr 12, 2023 2

DESIGN FOR OEE (DFOEE)

Apr 12, 2023 3

Making losses more transparent highlighting areasfor improvement during theDesign Stage of new production equipment

DFOEE Equipment Design Questions• How much operational cost can we save, equipment ROI

improvement?• What is the most effective throughput for the system?• How can we improve the “Six Big Losses”?• Which components must improve related to scrap?• How can we minimize transportation within the machine?• How can we minimize changeover time?• How can we design for product flexibility?• What are the safety and ergonomic concerns?• How to improve preventative maintenance (modular components)?• How can we simplify Autonomous Maintenance tasks?• Can the design combine the prior or next operation or both?• Can operation be simplified, improving training time?• How can we standardize the input and output for prior and next

operation?• Why is the flow left to right and the next operation right to left?• Can we optimize the footprint?

Apr 12, 20234

Design For Performance

• Increase speed – Switching from pneumatic to servomotors,

45% throughput increase

• Increase Speed– Limiting wasteful transportation of product

and application motion, 100% throughput increase

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Six

Big

Loss

es

Loss Category OEE Loss Category Examples

Breakdowns Down Time Loss • Tooling Failure• Unplanned Maintenance• General Breakdowns• Equipment Failure

Setup and Adjustments Down Time Loss • Setup• Material shortages• Waiting for next operation• Operator shortages• Major adjustments• Warm-up time

Small stops Speed Loss • Obstructed product flow• Component Jams• Misfeeds• Sensor Blocked• Delivery Blocked • Cleaning/Checking

Reduced Speed Speed Loss • Rough Running• Tool Wear• Under Design Capacity• Equipment Wear• Operator Inefficiency/ability

Startup Rejects Quality Loss • Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly

Production Rejects Quality Loss • Scrap• Rework• In-Process Damage• In-Process Expiration• Incorrect Assembly

6

7 Six

Seven

Big

Loss

es

Loss Category OEE Loss Category Examples

Waiting Down Time Loss • Product from previous operation• Information• Instructions• Skill

SYSTEM IMPROVEMENTS

Basic DFOEE Concept

>Equipment ROI & System

Flow

Equipment and Flow Losses

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Apr 12, 2023 9

System Approaches

Armand V. Feigenbaum

TQM

Apr 12, 2023 10

System Approaches

Taiichi Ohno

TPS

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System Approach

DFOEE

Apr 12, 2023

Design For OEE (DFOEE)

12

Process 120 Units/min

Process 215 Units/min

Process 320 Units/min

Design For FlowProcess 1 or 3 New Equipment Design to 30 Units/min is a Waste

= Process Output15 Units/min

DFOEE Team

Supplier Lean Sigma

Process Engineer Lead Operators

Equipment Design

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SYSTEM KNOWLEDGE

Which Process to Improve OEE

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Consider the O

Which Process to Improve OEE• Weighted Average Method• Value Added = Product Revenue –

COGS

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Process OEEValue Add

Value %

OEE Value

1 85.0% $44,320 22.5% 19.2%

2 60.0% $51,005 25.9% 15.6%

3 77.0% $42,315 21.5% 16.6%

4 82.0% $48,900 24.9% 20.4%

5 55.0% $10,100 5.1% 2.8%

Total $196,640 100.0% 74.5%

3.8%

20.8%

Vs

DFOEE Benefits• System flow improvements (Quality Cost Delivery)• COGS improvement• Improvement resources focused on value add• Reduced Equipment Operator training time• Fast changeover• Quality improvement• Reduced maintenance time and cost• Safety and ergonomic improvement• World Class OEEApr 12, 2023 www.leanteamsusa.com 16

Guaranteed ROI From Lean Teams USAContact Us

• Lean Teams USA Lean Consulting

• View My Profile on LinkedIn

• See my DFOEE Blog

• Lean Teams USA +1 215 353 0696

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