Optimizing performance: Achieve 98% OEE with efficient solutions

In the industrial sector, overall equipment efficiency (OEE) is a crucial indicator for assessing the performance of production lines. Achieving an OEE of 98% is very ambitious, but not impossible. It represents near-maximum utilization of production capacity, resulting in lower costs, higher productivity and improved quality. However, achieving this level of efficiency requires a detailed understanding of the factors influencing OEE, and a mastery of the tools needed to improve it. Without this rigor, bottlenecks, unplanned downtime or process variability can compromise a plant’s competitiveness.

There are often many reasons why an optimum OEE cannot be achieved: unplanned machine stoppages, operational inefficiencies, quality losses and sub-optimal production rates. These factors have a direct impact on productivity, generating delays and additional costs. For example, frequent stoppages, even for short periods, can severely drag down the average of an indicator that measures availability. In fact, every non-productive minute translates into significant financial losses. Poor control of these parameters can compromise market penetration, customer satisfaction and the company’s financial health.

To overcome these challenges and maximize OEE, companies need to adopt a combination of targeted strategies. Continuous improvement, such as Lean Manufacturing or Total Productive Maintenance(TPM), is essential to identify and eliminate waste. At the same time, the digitization of the shop floor, with tools such as those offered by TeepTrak, enables real-time data to be captured and operations to be constantly adjusted as required. Ongoing data analysis, via customized dashboards, will provide invaluable insights for anticipating drifts and proactively correcting course.

A case in point is an automotive parts manufacturing plant that integrated TeepTrak’s tracking system. Thanks to an in-depth analysis of their processes via thePerfTrak real-time tracking tool, the plant was able to identify that their biggest losses came from over-frequent and ill-prepared series changes. By specifically tackling these points, the plant reduced its idle times by over 30%, taking its OEE from 85% to 96% in just a few months. This success lies in a combination of digitalization for increased visibility and Lean methods for continuous optimization.

For plant and production managers, aiming for an OEE of 98% must be a structured project, integrated into the company’s strategic objectives. It is crucial to start with a complete assessment of current capacities and limitations, using an industrial ROI calculator, in order to prioritize actions. By equipping yourself with high-performance tools, such as those from TeepTrak, and cultivating a culture of continuous improvement, it is possible to achieve significant productivity gains. This approach will transform data into decisions, propelling the company to new heights of performance.

FAQ

Question 1: How does an OEE of 98% affect my business?

An OEE of 98% means near-maximum equipment utilization efficiency, reducing costs, increasing productivity and quality, and improving the company’s overall competitiveness.

Question 2: What are the first steps in improving my OEE?

Start by assessing your current performance with tools like the ROI calculator. Identify key yield loss points and implement real-time tracking solutions like those offered by TeepTrak.

Question 3: What role does digitalization play in OEE optimization?

Digitization plays a key role in enabling production data to be collected and analyzed in real time. This facilitates visibility across the entire production chain, and enables processes to be rapidly optimized to improve OEE.