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In the dynamic realm of manufacturing, achieving maximum OEE (Overall Equipment Effectiveness) remains a constant pursuit for companies aiming to optimize their operations. However, challenges such as machine downtime and team management often impede this endeavor. To address these hurdles and elevate OEE, manufacturers must adopt strategic measures tailored to their unique production environments. Here are some of the key strategies to enhance OEE and drive efficiency in manufacturing facilities:
1. Maximize machine efficiency
Machine breakdowns and equipment failures pose significant threats to OEE by causing unplanned downtime and production delays. To mitigate these risks, manufacturers should implement sound maintenance practices. By utilizing preventive maintenance techniques and optimal reactive maintenance process, organizations can identify potential equipment issues before they escalate, minimizing disruptions and maximizing machine uptime. Predictive maintenance is the final step to increase efficiency, but it can be implemented effectively only after the data from preventive and reactive maintenance is already digitalized.
A CMMS (Computerized Maintenance Management Software) is able to solve this issue and is a must in the pursuit of the enhanced OEE. Of course, the motivation and engagement of the team is a key factor. Our advice will be to choose a solution which is user friendly and easy for the technicians to use. Having mobile first view, such as Fabrico does, makes it easy for the technical team to adapt.
2. Thoroughly account for production stops and downtime
Understanding the root causes of production stops and downtime is essential for improving OEE. By meticulously documenting and analyzing instances of downtime, manufacturers can identify patterns and underlying issues affecting production efficiency, enabling targeted interventions to minimize disruptions and maximize equipment utilization. Usually, this data is recorded in the CMMS. Thus, the combination of CMMS and OEE functionalities gives the chance to achieve higher efficiency.
3. Eliminate the Six Big Losses
Incorporating lean manufacturing principles, such as addressing the Six Big Losses in manufacturing, enables organizations to identify and mitigate sources of waste and inefficiency in production processes. The Six Big Losses are:
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Unplanned Stops
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Planned Stops
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Small Stops
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Slow Cycles
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Production Rejects
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Startup Rejects
By targeting the above topics, manufacturers can optimize resource utilization and enhance overall equipment effectiveness.
4. Measure correctly
The integration of Internet of Things (IoT) and Industrial Internet of Things (IIoT) technologies revolutionizes data collection and analysis in manufacturing settings. By leveraging smart equipment and machinery, manufacturers can gather real-time data on productivity metrics, enabling immediate insights into equipment performance and production efficiency. With IIoT capabilities, organizations can access production reports, track OEE metrics, and analyze historical data swiftly, facilitating informed decision-making and proactive problem-solving.
Elevating OEE requires a strategic approach that integrates advanced technologies, proactive maintenance practices, and targeted improvement initiatives. By implementing lean strategies, combined with the right solutions, like CMMS, manufacturers can unlock the full potential of their production operations, minimize losses, and achieve sustainable improvements in overall equipment effectiveness. Embracing innovation and continuous improvement is key to thriving in today's competitive manufacturing landscape.
