SET-UP OBSERVATION FORM

Operator(s) Start End Part No. Operation time Step No. Changeover Element Element Elapsed Change over categories External Internal Waste Improvement Plan Goal of improvement Plan Internal to Eliminate external Reduce M/c. From To Area / Department Date

Totals Internal: Operations that necessitate the stopping of the machine. External: Operations not requiring the stopping of the machine. Key Terms: ASSEMBLE, DISMANTLE, USE, TAKE, TRANSPORT (FULL/EMPTY),PUT DOWN, FIND, ADJUST, INSPECT, REPOSITION, HOLD, WAIT, LOOK FOR.

135817930.xls.ms_office Observation

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SPAGHETTI DIAGRAM
Process Name:

Your Name: Location: Date:

135817930.xls.ms_office Spaghetti

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WASTE OBSERVATION
Location:
WASTE TRANSPORT OBSERVED

Name: Date: CAUSE

INVENTORY

MOTION

WAITING

OVERPRODUCTION

OVER PROCESSING

DEFECTS

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SEQUENCE CHART
Process Name:
PROCESS STEP

Your Name: Location: Date:

135817930.xls.ms_office Sequence

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LOAD CHART
Process Name: Operation

Your Name: Location: Date:

Operator

135817930.xls.ms_office Load

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GRAPH PAPER
Graph Name:

Your Name: Date:

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OVERALL EQUIPMENT EFFECTIVENESS CALCULATION FORM Date: Process/Machine name: Process/Machine number: Working Time Working Time: Planned meetings: Planned lunches/breaks: Planned maintenance/stoppages: Available Time: Availability Rate Available Time: Process/equipment failure: Process change over/set-ups: Start-up/waiting/unplanned meetings, breaks etc: Operating Time: Availability Rate % Performance Rate Operating Time: Idling, adjustments & minor stoppages: Performance loss: Process time for 1 part (actual): Process time for 1 part (optimal): difference:
X

Units of Time

min/day

(record average times lost across period observed) (all recordings are for process / m/c stopped only)

480 min/day min/day 30 min/day 10 min/day 440 min/day

440 min/day 45 min/day 50 min/day 15 min/day 330 min/day 75.0% 330 min/day 16 min/day

20 17.5 2.5
Units of time Units of time Units of time

Units produced in period (all shifts): Performance loss:

20 parts 50 min/day 264 min/day 80.0% 264 min/day 30 min/day 14 min/day 220 min/day 83.3%

Productive Time: Performance Rate % Quality Rate Productive Time: Time for Rework: Time for Scrap (use % of productive time): Effective Time: Quality Rate % Overall Equipment Effectiveness Availability Rate %
X

75.0% 80.0%
X

Performance Rate % Quality Rate % OEE

83.3% 50.0%

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OVERALL EQUIPMENT EFFECTIVENESS ANALYSIS

60

Losses min/day Breakdowns Changeovers Start-up Idling Speed Scrap&rework TOTAL LOSSES 45 50 15 16 50 44 220

50

40
30 20 10 0

OEE
Availability Rate Performance Rate Quality Rate OEE 75.0% 80.0% 83.3% 50.0% min/day Availability Loss Performance Loss Quality Loss OEE 110 66 44 220
OEE 50% Availability Loss 25%

Performanc e Loss 15% Quality Loss 10%

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IMPROVEMENT MONITOR
Location:

Name: Date:

PARAMETERS Changeover Time (last to first) External Time Internal Time Number of Set-up Steps Travel Distance (Man) Travel Distance (Mat'l) Travel Distance (Tools) Floor Space used OEE Value Added/Total Time Number of people req. (all shifts) Number of Error Proofs 5S Observation score 3D Observation score

UNITS Hrs Hrs Hrs

BEFORE

AFTER

IMPV'T

REMARKS

M M M M2 % %

% %

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5 WHY ANALYSIS
Problem/Issue:

Name: Date:

WHY 1

WHY 2

WHY 3

WHY 4

WHY 5

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ACTION PLAN
Date: Process/Location:
Enter 0,1,2,3,4

No. Issue

Action

Who

When

Prog.

135817930.xls.ms_office Action

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