Equipment Efficiency Improvement through Overall Equipment Efficiency (OEE)

28-29 Aug, 2023, Melia Kuala Lumpur

IPA Training is Registered with

Learn from the Best

Mr. P. Balachandran is a training consultant with over 18 years of experience in manufacturing and 23 years in training.


Mr. Balachandran began his career in the Equipment Maintenance function in Motorola Malaysia and grew steadily to become an Equipment Engineer. He later took on a position as Section Head for a Production Unit which he ran for several years. He moved on to Thomson Audio Electronics in Muar as a Production Manager in 1991 where he spent 2 years.


Subsequently, he assumed a position as Production Manager and then as a Training and Education Manager at Samsung Electron Devices, Seremban till 1995 and then became a full time trainer in july 1995.


Mr. Balachandran specializes in Equipment Maintenance, Manufacturing and Training. since becoming a manufacturing trainer, he has conducted more than 700 training sessions covering more than 14,000 participants both in-house and public programs in last 23 years.


He currently is one of the most prominent maintenance consultant for theoretical and subject matter expertise. He also specializes on TPM and have conducted numerous in-house training for the above topic. Mr. P. Balachandran is one of the most prominent trainer and consultant for RCM training and consultation.

Venue Details

Melia Kuala Lumpur
16 Jalan Imbi,
Phone : 0 3 2785 2828 /malaysia/kuala-lumpur /melia-kuala-lumpur

Contact us

03 2283 6109

03 2283 6100 

03 2283 6101

A-28-5, 28th Floor, Menara UOA Bangsar, 
No.5, Jalan Bangsar Utama 1, 
59000 Kuala Lumpur

  • Module 1: Equipment Efficiency in Manufacturing
  • Module 2: TPM’s 8 Major Equipment Losses
  • Module 3: Measure Overall Equipment Efficiency
  • Module 4: Improving Availability
  • Module 5: Improving Performance Efficiency
  • Module 6: Improving Rate of Quality
  • Module 7: Proactive Maintenance Strategies

Current manufacturing organizations heavily depend on their equipment productivity for achieving their PQCDSM. Profit and loss of a company directly depends on how well the company manage and utilize their assets to the fullest. Are we getting the full efficiency? This is the big question that every manufacturing head is left to ponder with.

Many organizations depend on lowest down time as the mark of good productivity. Are the down time indices measure efficiency? down time only measures the time taken for repair and do not reflect equipment reliability. Down time itself is reactive and not proactive.

What we need is a formidable method that will highlight all kind of weaknesses in our manufacturing area. Many a time we think, the maintenance inefficiency is the direct cause for missing targets. this have been proven wrong many times through in-depth analysis.
- how good the equipment run without failure?
- how efficient the production use the equipment?
- how reliable is the equipment to produce good part?

These are the three criterias that determine the equipment efficiency.

The OEE methodology, a part of TPM’s KOBETZU KAIZEN, help manufacturing organizations to really identify their actual equipment efficiency and determine where the losses are coming from.

Being in the manufacturing environment for more than 40 years, OEE is a well accepted methodology that helps manufacturing to achieve and excel in their quest for manufacturing excellence .

  1. Every team would have done one actual OEE for selected line.
  2. Knowing how and what data must be collected and used.
  3. Being able to understand 8 major equipment losses.
  4. Knowing what brings down OEE.
  5. Knowing how to measure reliability, efficiency and capability.
  6. Being able to know the 8 strategies for zero breakdown.
  7. Improving production efficiency.
  8. Being able to know how to improve equipment quality capability
Managers, Engineers, Supervisors, Technicians of Production, Maintenance, Process, Quality and R&D.
Production Managers are a must because they are the one who should lead the team since they are the ultimate beneficiary in this cours
  • Interactive Lectures
  • Explanations
  • Case Studies
  • Group Discussions
  • Q & A Sessions

Module 1: Equipment Efficiency in Manufacturing

  • Changing equipment dependence
  • The three cultures of maintenance
  • Contribution of breakdowns to co$$$$t
  • Why equipments must run efficient?
  • Introduction on TPM concepts
  • The 16 major manufacturing losses


Module 2: TPM’s 8 Major Equipment Losses

  • Scheduled down time
  • Breakdown losses
  • Setup and adjustment losses
  • Cutting blade losses
  • Startup losses
  • Minor stoppages
  • Speed losses
  • Defect & rework losses


1:00 Lunch

Module 3: Measure Overall Equipment Efficiency

  • TPM’ s ultimate tool for measuring equipment efficiency
  • Understanding manufacturing time structure
  • Constituents of planned/unplanned down time
  • Availability
  • Performance efficiency
  • Rate of quality
  • Overall equipment efficiency formula

Team Activity 1 : Compute OEE for selected line



Module 4: Improving Availability 

  • Why equipments breakdown?
  • Measuring equipment breakdown (MTBF, MTTR)
  • Breakdown improvement strategy
  • Causes of setup time losses
  • Improving setup and changeover

Team Activity 2 : Calculate MTBF, MTTR for selected line


5:00 End of Day 1

Module 5: Improving Performance Efficiency

  • Measuring minor stoppages
  • Improving minor stoppages
  • Measuring speed losses
  • Strategies for speed improvement

Team Activity 3 : Calculate MTBA, speed losses


Module 6: Improving Rate of Quality

  • What is rate of quality?
  • Measuring rate of quality
  • Strategies for reducing defects

Team Activity : Calculate quality losses


1:00 Lunch

Module 7: Proactive Maintenance Strategies 

  • Autonomous maintenance
  • Scheduled planned maintenance
  • Predictive maintenance
  • Poka yoke
  • Discard maintenance
  • On-going continuous improvement (kaizen)


5:00 End of Course