Understand OEE and the six major losses to improve your production

In today’s industrial world, optimizing overall equipment efficiency, or OEE (Overall Equipment Effectiveness), has become a key factor in improving competitiveness. Yet many plants still struggle with the six major losses identified by TPM (Total Productive Maintenance) methodology that significantly reduce OEE. These losses include problems such as unscheduled stoppages, reduced speed, and frequent breakdowns, all of which have a direct impact on a company’s productivity and bottom line.

The root causes of these losses are often linked to inadequate maintenance, insufficient staff training, or a lack of real-time data monitoring and analysis. Their impact is measured in terms of increased downtime, lower product quality, and higher production costs. A low OEE rate means that machines are not working to their full potential, resulting in wasted resources and lost revenue for the company.

To address these challenges, companies can adopt a number of effective strategies, such as deploying an advanced digital solution like TeepTrak, which facilitates real-time monitoring and analysis of equipment performance. Implementing Lean and continuous improvement practices also requires in-depth analysis and key indicators such as OEE to identify bottlenecks and optimize production processes.

A concrete example is a production line in an automotive plant where the OEE was clearly insufficient due to frequent breakdowns and reactive maintenance. By integrating TeepTrak tools, the plant was able to monitor performance data in real time, reduce machine downtime and increase its OEE by 15% in less than a year. This success was made possible by detailed analysis of the causes of breakdowns and proactive planning of maintenance interventions.

For an industrial company to maximize its performance, it is crucial to measure, analyze and continuously improve its OEE. Digitization, thanks to solutions such as those offered by TeepTrak, provides an accurate overview of production, facilitating informed decision-making. Starting with an audit of current losses and implementing appropriate metrics can significantly reduce losses and boost plant efficiency.

FAQ

Question 1: What are the six major production losses?

The six major losses include breakdowns, set-ups, small stoppages, speed reductions, quality defects and start-up stoppages. Understanding each of these losses is essential to maximizing OEE.

Question 2: How does TeepTrak help improve TRS/OEE?

TeepTrak provides real-time monitoring and analytical data to quickly identify inefficiencies, reducing downtime and optimizing production line productivity.

Question 3: Where do I start to improve my plant’s efficiency?

Start with a comprehensive audit of current performance. Identify your main losses and implement digitalization technologies and Lean strategies for continuous monitoring and improvement.