In the manufacturing industry, calculating speed losses when measuring overall equipment efficiency (OEE) is crucial. This problem can have a profound impact on plant productivity. When a machine runs below optimum capacity, inefficiencies creep into production. These losses are not just limited to reduced output, but also hinder rapid reaction to failures and limit operational flexibility. That’s why it’s so important for plant and production managers to master the calculation of speed losses, so they can better manage their production lines.
The causes of speed losses are varied. They are often the result of equipment under-utilization, non-optimized operations or uncontrolled changes in production rate. What’s more, they have a direct impact on OEE/ROS by increasing unplanned downtime, reducing output quality and generating additional operating costs. A lack of visibility on these losses can even lead to inappropriate reinvestment decisions. In-depth analysis of the causes underlines the priority of monitoring these elements to maintain a high level of performance.
To remedy these losses, several levers of action are available. The first step is the precise identification of bottlenecks through performance indicators. Implementing real-time monitoring, thanks to solutions such as those from TeepTrak, enables performance to be accurately tracked and analyzed. Optimized organization and implementation of continuous improvement methods, such as Lean Manufacturing, also bring proven results in terms of quality and availability. Finally, the digitization of the shop floor completes this approach by providing total transparency of operations.
A concrete example illustrates the transformation possible thanks to effective speed loss management. In a plant producing electronic components, the integration of TeepTrak’s Real-Time Performance Monitoring solution identified that lines were operating at only 85% of their ideal capacity. By analyzing the data, the plant was able to readjust production rates and train its teams, reducing speed losses by 20%. This led to an immediate increase in OEE and a significant reduction in waste.
For manufacturers seeking to optimize their OEE, it is crucial to regularly measure equipment performance and adopt a proactive approach to continuous improvement. With high-performance monitoring tools, such as those offered by TeepTrak, you have increased visibility of your operations, enabling you to effectively target the actions you need to take. It’s time to launch a digitalization project for your workshop, to transform these losses into opportunities for profit.
FAQ
Question 1: How do I start calculating OEE speed losses?
To get started, it’s essential first to measure current production speed against the equipment’s rated capacity. Evaluating deviations will help you target specific losses.
Question 2: What impact do speed losses have on TRS?
Speed losses reduce the Synthetic Efficiency Ratio (SER), as they directly affect the optimum utilization of your equipment, increasing costs and reducing output quality and quantity.
Question 3: Where do I start to improve the OEE of a production line?
First, identify key performance losses using real-time measurement tools. Then, apply continuous improvement methodologies to progressively adjust and optimize your processes.
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