“Leverage the strength that you have: that no one else can be you.”
- Todd Wheatland
OEE
Overall Equipment Efficiency Program
Continuous monitoring and recording of the production performance of a single machine or a group of equipment is the first step towards understanding how to utilize these assets in an efficient and cost-effective manner.
Take for example a typical manufacturing industry say packaging industry which has equipment like offset press. A typical offset press configuration used for Packaging is say a 6 colour plus coater. This is an expensive piece of hardware that has to be utilized to its fullest for the print shop to make substantial profits. If the machine utilization is not satisfactory, some tough questions have to be asked. Where are we going wrong? Are the make-ready times too long? If so, is it because the operators are not trained well? Is the machine waiting for plates to be delivered from the Pre-Press department? What about the job changeover times? Is wastage within acceptable limits or not?
Our Overall Equipment Efficiency Program (OEE) will help you with the answers to such questions by giving you quantifiable data that you can use to make decisions appropriate to the situation. This specially tailored programme focuses primarily on improving the overall business performance by statistical analysis of real-time data captured from the shop floor of a specific production environment.
Successful implementation of OEE in an organisation can result in a substantial positive impact on bottom line.
- An increase in OEE of around 10% can translate to a 50% improvement in Return on Assets investment.
- OEE initiatives are generally ten times more cost-effective than purchasing additional equipment capacity and over a period of time, can reduce major capital expenditure by 50%.
- In many major industries, an improvement of 1% in reduced downtime of a high value asset can result in a fivefold savings in cost.
- As machine OEE increases, total energy consumption per unit produced is reduced and contributes in implementing a lean production process.
- Wastage of material can be very largely controlled.
Scope Of Work:
- Introduction of concept to the production team.
- Providing or customizing templates for production data capturing.
- Setting up of team and providing training for capturing master data.
- Compiling and extrapolating the data.
- Identifying the weak areas and deriving measures to correct the deviations.
- Guiding the process over a period till the team can carry out the task on their own as continuous improvement
process.
Duration:
- Introduction of the concept, data gathering, training and analysis (3 days)
- Three Monthly visits for auditing and course correction of 2 days duration (6 days)