Why your OEE needs special attention: Diagnosis and Solutions

In today’s industrial world, achieving optimum performance on production lines is a crucial issue. However, many plant managers wonder ‘why their OEE is not expressing its full potential’, to the point of attracting attention by atypical signals, such as ‘whistling’. Synthetic Efficiency Ratio (SER) is a key indicator for measuring equipment efficiency. Understanding ‘why OEE is still perfectible’ can help maintain competitiveness and reduce high production costs.

The causes of poor OEE performance are often multifactorial. Unplanned downtime, excessive quality variability, or sub-optimal production speeds are all potential culprits that put a strain on productivity. Poor OEE can also result from a lack of accurate data, or misinterpretation of data, leading to uninformed and often costly decisions. The result is longer lead times, increased waste and a high level of wasted resources.

To reverse this trend, several levers can be activated. Firstly, adopting continuous improvement methods such as Lean Manufacturing can help identify bottlenecks. Digitizing the shop floor with a solution like TeepTrak enables real-time monitoring of performance, offering greater visibility over the entire production process. Using analysis tools to segment production data in real time is also essential for identifying sources of efficiency loss and taking effective corrective action.

Let’s illustrate this with a real-life case: an automotive parts manufacturing plant was observing an OEE below expectations due to repeated interruptions on several workstations. By integrating TeepTrak, the team was able to track downtime precisely, and pinpoint a particularly faulty machine causing a chain of interruptions. Thanks to digitalization, they reduced downtime by 30% and significantly improved overall OEE, thus meeting expected performance standards.

In conclusion, understanding ‘why your OEE is whistling’ is essential for any company seeking to optimize its industrial performance. It’s best to adopt a continuous measurement system, such as that proposed by TeepTrak, which provides clear objectives and quickly identifies sticking points. The key is to draw up a targeted action plan now, based on the data collected, to guarantee continuous improvement in your OEE. Start with a production process audit, deploy relevant indicators and structure a sustainable optimization strategy.

FAQ

Question 1: How do I know if my OEE is sufficient?

A good OEE is generally between 85 and 95%, depending on the industry. Compare this with your production targets and analyze any discrepancies.

Question 2: What is the impact of a low OEE?

A weak OEE translates into inefficiencies, wasted resources and potentially reduced competitiveness. Correcting these problems is a strategic priority.

Question 3: Where do I start to improve my OEE?

Start with a production line audit to identify bottlenecks, and consider implementing a tracking solution like TeepTrak for real-time control.