Optimizing OEE in the face of declining performance

In today’s industrial context, declining overall equipment efficiency (OEE) can represent a serious challenge for plants. WhenOEE shows a downward trend, it can indicate productivity losses, prolonged downtime or poor production quality. A “declining” OEE jeopardizes a company’s competitiveness and profitability, so it’s crucial to keep a close eye on this indicator.

There are a number of possible causes for a drop inOEE. Often the result of inadequate maintenance, inefficient processes or lack of operator training. Extended downtime, whether planned or unplanned, directly affects machine availability. In addition, high rates of scrap or rework increase production costs, negatively impacting overall OEE. Every plant, especially those that have not fully embraced digitalization, is exposed to these risks.

To reverse this trend, available solutions include the adoption of continuous improvement methods such as lean manufacturing and total productive maintenance. Digitizing the shop floor with solutions like TeepTrak’s can provide real-time visibility of equipment performance. By measuring OEE with sophisticated tools, plants can identify failure points more quickly and optimize operational processes accordingly.

A case in point is an electronic component manufacturing plant, where OEE had fallen from 75% to 60%. By working with TeepTrak to deploy a real-time OEE and performance monitoring solution, the plant was able to analyze the root causes of the downtime and implement targeted corrective measures. This enabled them to turn around their OEE to 78% in six months, boosting equipment reliability and improving the quality of finished products.

For any company looking to improve its OEE, it’s crucial to start with a detailed audit of the existing situation, followed by a rigorous implementation of appropriate solutions. By continuously measuring results, adjusting strategies and integrating tools like those offered by TeepTrak, current challenges can be transformed into concrete opportunities for improvement. Don’t let an unexplained drop in OEE/ROS undermine your competitiveness: commit today to an effective monitoring and optimization action plan.

FAQ

Question 1: How can we identify the causes of a drop in OEE?

To identify the causes of a drop in OEE, start by analyzing equipment data in real time. Monitor key indicators such as availability, performance and quality to detect anomalies.

Question 2: What is the impact of digitalization on OEE?

Digitization enables better real-time visibility of performance, making it easier to detect inefficiencies and optimize processes. This reduces downtime and improves quality, thus increasing OEE.

Question 3: Where do I start to improve a plant’s OEE?

Start with an audit of current processes to identify bottlenecks. Then implement continuous improvement methods and digitalization tools for ongoing measurement and optimization.