OEE (Overall Equipment Effectiveness) is a key performance metric used in pharmaceutical production (as well as in other manufacturing industries) to assess the efficiency and productivity of equipment. It combines three fundamental factors: Availability, Performance, and Quality, and it helps identify losses in the production process. These three factors are used to calculate a percentage that reflects the overall effectiveness of equipment in producing quality products efficiently.
Overall Equipment Effectiveness (OEE) Calculation Formula
OEE = Availability (A) × Performance (P) × Quality (Q)
Where,
Availability (A) = Operating Time / Planned Production Time
Performance (P) = (Ideal Cycle Time × Total Units Produced) / Operating Time
Quality (Q) = Good Units Produced/ Total Units Produced
For example, if during one shift (8 hrs) a machine has been running for 7 hrs and it was standing still for 1 hrs because of repairs, then
Availability (A) = 7/8 = 0.875 (87.5%)
If the optimal speed for the product is 50 units/min but machine was making only 45 units/min, then
Performance (P) = 45/50 = 0.90 (90%)
When some of the products have been rejected, this is quality loss. Out of the 3000 units produced in an hour, 200 were not according to the specification, then
Quality (Q) = (3000-200)/3000 = 0.933 (93.3%)
Now,
OEE = A × P × Q = 0.875 × 0.90 × 0.933 = 0.735 or 73.5%
Benefits of OEE in Pharmaceutical Production:
- Identifies bottlenecks and inefficiencies.
- Helps improve equipment utilization.
- Aids in continuous improvement initiatives by pinpointing specific areas for improvement.
- Ensures a balance between maximizing production and maintaining high-quality standards in pharmaceutical manufacturing, where regulatory compliance and safety are critical.
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