Overall Equipment Effectiveness

OEE (Overall Equipment Effectiveness) is the gold standard for measuring manufacturing productivity. Simply put - it identifies the percentage of manufacturing time that is truly productive. An OEE score 100% means you are manufacturing only Good Parts, as fast as possible, with no Stop Time. In the language of OEE that means 100% Quality (only Good Parts), 100 % Performance (as fast as possible), and 100% Availability (no Stop Time).

OEE & downtime monitoring system helps to pinpoint loss factors within the production environment. The data can be analyzed and viewed from different angles, facilitating the detection of significant interrelationships. The insights gained help to formulate well founded improvement measures.

In addition to the implementation of an OEE analysis capability, we assist you in the development of individual production control procedures and the definition of an integrated data model based on data availability within your installation.

Understand and reviewing historical OEE data is useful in identifying the root causes of production capacity loss. Moving a step further, having real - time OEE data helps both production managers and operators to mitigate, if not swiftly resolve production problems before they escalate into serious bottleneck situations.

Making real - time OEE data available on the production floor

For many years, operators have been manually calculating OEE, often at the end of the day. While managers and operators have worked hard on using the retrospective data to make error corrections and improve on productivity, manufacturers continued to face the challenge of correcting problems as they occur. This poses a threat to the prouction line as upstream or downstream breakdowns have a direct impact on Availability.

Real - time OEE data is more than just an amalgamated OEE score. It provides real - time performance metrics and detailed but visually-effective analytics on the production lines and equipment. For instance, our software solutions can categorise and quantify the causes of the unplanned and planned stops affecting the equipment.

With real - time OEE data displayed on the production floor, supervisors can work together with the relevant operators to make simple yet effective adjustments such as staggered break times to reduce the number of planned stops as much as possible. Furthermore, having a live - display provides greater transparency on the performance of each operator, and it serves as healthy motivation for them to become even more efficient.

Cultivating individual responsibility to reduce performance loss

Many a little makes a mickle. Conversely, frequent small stops may lead to significant production losses in the long -run. Before having real - time OEE data, operators may have been overlooking the short spurts of machine downtime as a result of small stops. As such, they might have accepted the status quo and did not think of ways to improve it. 

With real - time OEE, operators might become more invested in preventing such stoppages and thought more critically of ways to fix the problems. They could perhaps sound out to their managers on the diminishing returns of using an outdated machine and suggest further improvements. This new sense of awareness and responsibility for their work is known to have a positive spill - over effect on their colleagues. As a result of which, companies have often seen an increase in OEE from 10 to 20%.

Validating investment decisions

Purchasing new production equipment can be expensive and poor investment decisions could result in long - term debts of at least 10 years. On the one hand, it is more economical to spend the money on maintaining and repairing existing machinery. On the other hand, historical data have shown that current production levels are falling below expectations and the company suspects that the existing equipment is no longer performing.

With an OEE hovering at a mere 40% should the company purchase new types of machinery to increase output or is it unnecessary? During such pressing times, real - time OEE data can help us do the math and make more informed decisions.

By working with the operators, technicians and supervisors to monitor real - time OEE data, insights may be gathered to show that existing equipment is working perfectly fine. The culprits for low production levels were mainly due to the under - utilised pockets of production time where many types of machinery were idling more than they should. As we can see, through the simple act of monitoring OEE data, the company would know exactly how they can run existing ones more effectively and increase productivity without breaking the bank.

Bringing positive changes to your production floor

OEE is more than just a number. Coupled with the correct analytical tools and a committed team, any manufacturer can successfully visualise, quantify and minimise their production loss. In the labyrinth of information and KPIs to meet, OEE helps companies and manufacturers to be laser - focused on the necessary areas of improvements and achieve maximum results. If you are keen further explore the untapped potential of your production plan, HAS-i is here to help.