Overall Equipment Effectiveness (OEE) Improvement
Overall Equipment Effectiveness (OEE) Improvement Eliminating waste and improving the efficiency and effectiveness of the output
In a dynamic market scenario, businesses want to make the maximum and efficient use of their available resources and machinery for faster delivery of products/services that value their customers. They also want to ensure that their products/services reach the customers on time with desired quality, with no rejection. In view thereof, any delay, machine downtime, resource unavailability, and inefficiency can cost businesses a loss of valuable customers.

Therefore, there is a crucial need to adopt Lean Manufacturing approach into the operational processes that can eliminate the waste and Non-Value Added Activities (NVAs). Businesses need to focus on optimizing products/services/process that can add value to their customers and at the same time can promise cost reduction.

The customer is willing to pay only for things that can add value. Everything else is waste and should be reduced, eradicated, simplified or integrated.

It is crucial to calculate the amount of waste and equipment effectiveness of your plant so that the production cycle can speed up with zero downtime, defects, and accidents. And, this is calculated through Overall Equipment Effectiveness (OEE).

Calculate the overall Equipment Effectiveness

What is OEE?

A part of Lean Manufacturing, OEE is a plant performance parameter that calculates every machine’s availability (uptime), its performance, and its production quality. OEE is measured in percentage, and it gives a complete picture of your machine’s health. It determines the percentage of manufacturing time that is truly productive for your plant. It applies to machines, equipment, and industrial assets.

The Challenge

It is essential to digitize and consolidate all the data required for production to calculate accurate OEE and then work on improving the same. But, the most significant challenge here is the lack of a robust centralized system that extracts data from a diverse landscape of various types of industrial PLCs, sensors, and controllers installed in a plant.

Moreover, to introduce such a centralized system, it requires expert skills to identify the NVA parameters, design a solution to overcome them and monitor the implementation of the same. This is where PBOPlus helps.

Overall Equipment Effectiveness Challenges

How PBOPlus helps?

PBOPlus helps in optimizing the OEE of your plant. We start by diagnosing your processes to identify the loopholes and NVA parameters. We examine every machine, all parts and equipment. We gain deeper understanding about how your plant processes and machines need to work.

Our aim is to standardize your processes, improve the longevity and effectiveness of your machines, and ensure that your plant runs at full capacity. We help you know the actual plant capacity and more importantly, the areas where cost reduction is possible.

We convert your lagging factors into the leading ones by implementing the latest technology (ERP, Automation, IoT, and Robotics) wherever viable to speed up the process.

Our approach

PBOPlus believes that OEE improvement is not a one-time process. It requires a continuous course of actions to bring incremental improvements over a regular interval of time to reduce waste, enhance workplace functionality, customer service, and product performance.

We start with gap analysis. We investigate:
  • Where did the machine fail?
  • Why did it fail?
  • How did it fail?
  • How it is impacting the timeline and cost?
  • What are the steps for improvement so that the product delivery is not delayed?
On the basis of the above investigation, we plan preventive maintenance and conditional monitoring of the machines to eliminate the breakdowns. And, to manage and track this effectively, we employ our native model called 3TSOP which defines Test, Tolerance, and Target.
We employ the 3TSOP model to perform the breakdown analysis
  • We prioritize the breakdown that is greatly impacting the balance sheet.
  • We identify equipment that produce the lowest in the entire chain and define the Critical Constraint Machine (CCM).
  • We carry out a critical analysis of the machine to check how the change that we are planning to bring can affect the final outcome in terms of quality, time, and cost.
We do outside machine analysis
  • We control the environment around the machine by introducing a habit change in machine maintenance.
  • We propose a machine health checkup plan where every machine is examined for cleaning, lubrication, retightening, and inspection (CLRI) following 3TSOP.
  • This approach can improve your OEE from 50 to 70 percent.
We do inside machine analysis
  • We study the entire lifecycle of the machine to figure out the potential design flaw and worn out parts.
  • We investigate if a part of the machine or process is malfunctioning and to what level it is affecting the output.
  • We analyze that if the part/ process can be replaced by the introduction of ERP, Automation, IoT, and Robotics.
  • This approach can improve your OEE from 70 to 85 percent.
We reduce the machine downtime
  • We introduce production performance management exercise in your plant that includes condition monitoring, process and quality monitoring, and predictive maintenance of machines.
  • This improves the availability, performance, and quality of the machines. And, this eventually improves the OEE of your plant.

The process doesn’t stop here. To attain the maximum OEE, continuous efforts towards eliminating the waste and maximizing the output are inevitable. Therefore, we keep on refining our model 3TSOP with respect to the changing demands of your product customization, innovation, and outcome.

To know the actual OEE of your plant contact us. Seek help from our experts to improve your plant performance. We will happily assist you even at the oddest hour of the day.