This product is designed as part of a training exercise to teach the principles of Overall Equipment Effectiveness (OEE) by simulating the problems encountered while operating an automated manufacturing system. The simulation electronically mimics all the functions and characteristics of an actual machine in the workplace and enables trainees to develop efficient operating procedures and maintenance schedules which may then be applied to the factory environment.

The main principles of the game and the control functions are described in detail below:

The machine is set up to produce a range of 5 different virtual products, each of which takes a different amount of time to produce. The trainees are given various roles such as machine operator, maintenance, supervisor, etc. and a typical production schedule showing the quantity of each product required in the allocated time. It is necessary to shut down the machine before changing over from one product to another. The start and stop procedure is also time consuming.

The operating conditions of the machine are indicated on the front panel displays. The three displays to the left show the power consumption, operating speed and oil reservoir level respectively. The machine operator may adjust the running speed of the machine but must also be aware that an increase in speed will also cause an increase in power consumption. The machine also consumes oil while it is running and the level in the reservoir needs to be maintained otherwise excess wear will be caused. The effects of this will become noticeable as the machine begins to slow down and the power consumption starts to increase.

The condition of the machine will also have an effect on the quality of the products manufactured. A badly maintained machine will produce more rejects than a well looked after machine. The number of good and bad products made is shown on the displays at the right hand end of the front panel.

The machine also simulates actual wear and tear on its component parts. There are 3 removable parts inside the machine, simulating actual components, which show their condition using four coloured lights on each part. A green light shows that the component is in good condition but any build up of wear will cause a yellow light to show and eventually a red light will show. When this happens the machine will be brought to a halt as the component has failed completely and needs to be replaced by the trainee appointed as maintenance operative. The number of spare parts is limited (as in real life) so the trainees are encouraged to maintain the machine correctly. The lengthy stoppage for repair also causes the production output to be considerably reduced. Preventative maintenance can also be carried out while the machine is running to reduce wear and prevent failure of the component parts.

The machine also contains a simulated fuse, similar to the parts described above. A badly maintained machine will consume more power than a good machine. Failure of the operator to monitor the power indicator and attempting to run a worn machine at high speeds will cause a power overload and the fuse will blow. This will cause the machine to stop and the production output will once again be compromised while the fuse is replaced.

The simulated parts will automatically reset themselves after approximately 10 minutes so that they can be used again in the next simulated production run.

The trainees take on the roles of the various production operatives, maintenance operatives, supervisors and quality controllers in order to simulate a realistic scenario, including scheduled breaks, shifts, rotas, etc. At the end of each session the trainees can calculate the OEE figure using the data produced during the production run. The trainees can then discuss possible areas for improvement, better operating and maintenance procedures, etc. and then run the game again to test out their new theories.

The end result is that more efficient use of machinery is obtained by learning better operating methods and working practices which will maximise production line efficiency.

The game is supplied complete with detailed instruction manual, transit case and 1 year warranty.