Measure and Improve: Optimizing Factory Efficiency with the Right OEE

In the competitive world of industry, optimizing production with OEE is key to achieving maximum operational efficiency. An essential tool for assessing and improving this efficiency is OEE (Overall Equipment Effectiveness). However, to obtain the greatest benefits, it is crucial to identify and analyze the right aspects of OEE that are relevant to each particular factory, taking into account each of its processes. In this article, we will explore which aspects of OEE should be analyzed to optimize production with OEE and maximize efficiency in different manufacturing contexts.

OEE is a comprehensive and universal metric and universal which provides a complete picture of how equipment and machines are performing in a production plant. It is calculated by multiplying three factors: Availability ( machine downtime), Performance (speed), and Quality (product rejection).

Determining whether your factory’s OEE is right or wrong involves a detailed analysis of the different aspects of OEE and how they align with the objectives and standards of the company and the specific sector to which it belongs. The key is to use OEE as a tool to identify areas for improvement and take corrective action to increase production efficiency.

The “ideal” OEE can vary depending on the type of industry, specific production processes and company objectives. There is no single number that defines the perfect OEE, as what is considered efficient can vary depending on the circumstances and goals of each factory.

Starting from the premise that we cannot define an “ideal” OEE %, we will highlight which aspects are key to obtain an objective and real value in our company.

To get a clear picture of OEE, it is essential to collect accurate, real-time data. This can be achieved through automatic monitoring systems such as MES systems with the help of sensors on the machines, or even manual records if necessary. Accurate data is crucial for effective improvement.

Analyzing OEE helps identify bottlenecks in production. It can reveal machines that are consistently inefficient or processes that cause quality problems. By addressing these critical points, obstacles to smooth and efficient production can be removed. or generate preventive maintenance plans that help us to eliminate inefficiencies in production due to the poor condition of the machine..

Continuous improvement is critical in maximizing OEE. Once problems have been identified, it is important to implement changes and measure their impact on OEE. Applying Lean Manufacturing and Six Sigma methodology will enable advantageous changes in operations management. This can include everything from adjustments to maintenance procedures to investing in automation for repetitive, high-wear work points for plant personnel.

If we carry out these recommendations we will achieve stability in our OEE % as a first item. Once we are “stable” in our efficiency, we will work on the lowest KPIs, reviewing the reasons for these decreases in order to find solutions to these inefficiencies. Among the many solutions that can be implemented in the industry to improve OEE, we list below some of the most significant ones.

By analyzing OEE availability, a factory can implement predictive maintenance systems. This involves using data to predict when failures are likely to occur and performing preventive maintenance rather than waiting for machines to break down.

A detailed analysis of OEE performance can reveal opportunities to increase production speed. This can be achieved by optimizing machine parameters, adjusting production cycles, or even investing in faster, more efficient equipment. Sometimes these optimizations lead to a significant increase in the profit margin on the manufacture of the product in question.

To improve quality, factories can integrate real-time quality control systems. This involves detecting defective products as they are being produced, allowing for immediate corrections and waste reduction. In addition, detailed audits and analysis can identify the root causes of problems in quality control procedures and throughout the production process flow.

It is important to remember that OEE is not a static metric; it must be continuously monitored and adjusted to maintain high levels of efficiency. In addition, different industries and processes may have different efficiency standards. For example, a food plant may have a slightly different optimal OEE than an automotive plant due to variations in processes and quality requirements.

Each company should set its optimal productivity target based on historically collected data and work internally with the various options listed above to achieve its target or at least maintain it so as not to enter into economic losses.

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