What Is OEE in Manufacturing and How Can It Be Improved?

1.1 Preventive maintenance: Schedule regular maintenance to avoid unexpected breakdowns.

Example: Plan time-based (weekly, monthly, semi-annual, and annual) or usage-based (numbers of work hours) periodic checks for machine lubrication to reduce unplanned downtime.

1.2 Minimize changeover time: Use SMED (Single minute die exchange) techniques to reduce changeover times.

Example: Organize tooling, parts, and components needed for the next product run (order) before the current or previous run (order) ends.

1.3 Improve scheduling accuracy: Ensure accurate production schedules and avoid machine downtime between orders.

Example: Look for a lower rate of change and wait between orders using a consistent schedule to avoid machine downtime.

1.4 Monitor and optimize downtime events follow-up: Track and analyze all reasons for downtime to implement targeted improvements.

Example: Use a downtime tracking system to track the events, detect trends in the data, and identify areas of opportunity to reduce the root causes of unplanned downtime.

1.5 Implement autonomous maintenance: Train operators to perform basic maintenance tasks that help avoid downtime.

Example: Clear maintenance procedures or electronic operating systems (electronic SOPs) can help operators perform simple tasks that prevent major problems.

2.1 Reduction/control of cycle time: Analyze and optimize machine speeds to minimize time per unit.

Example: Do tests or consult your manufacturer to make machine configuration adjustments that optimize speed without sacrificing quality. Consider the capacity limit with necessary quality as a setup margin.

2.2 Eliminate micro stops: Identify and solve small stops (no matter how minor) whenever they slow down production.

Example: A small but recurring problem can be more damaging than an unusually large one; a sensor that fails every 100 pieces in production of millions for a second is more worth it than trying to solve an unusual event that lasted 2 hours.

2.3 Optimize flow and availability of materials: Guarantee materials always available, at the right time and place.

For example, use a Kanban system to avoid material shortages or apply a stock check before starting.

2.4 Improve operator efficiency: Train your operators or equip them with accelerated execution models to make their execution more efficient and minimize delays.

Example: Implement electronic continuous training systems, use guided operating systems, or support processes with electronic procedures to reduce operator errors that cause slowdowns.

2.5 Standardize best practices: Develop and enforce standard operating procedures to ensure consistent performance.

Example: Design and use understandable standardized procedures that contain checklists and information tracking with the option of continuous improvement and direct communication. A standardized operation guarantees adequate and consistent results for its objectives.

3.1 Implement real-time quality monitoring: Use sensors and software that allow you to evaluate quality during production.

Example: Installing a vision system that rejects defective parts, adding an automatic good parts counter, or an electronic reporting system for the acceptance/rejection of parts will allow you to manage your quality more efficiently and actively.

3.2 Reduce process variability: Standardize and control process parameters to ensure consistent product quality.

Example: Apply statistical process controls (SPC) by monitoring equipment sensors and use that analysis to adjust machine settings based on real-time data.

3.3 Train the operator in solving quality problems: Provide exhaustive training on machine operation vs quality standards.

Example: Train your operators on how to detect and prevent defects during production and train them on how to solve them or provide correct follow-up.

3.4 Implement RCA (root cause analysis) for defects: Analyze defects to find and fix the root causes of problems.

Example: Use fishbone diagrams to investigate and resolve recurring quality problems or apply cause trees to find root causes.

3.5 Automated inspections: Automate inspections in early strategic areas to detect defects in the early or key stages of the process.

Example: Break down your process into key quality pain areas and consider strategic inspection points where you can integrate in-line inspection cameras to detect defects before products reach final inspection.