This is one of the main questions that we repeatedly get asked.
- So you want to record your OEE properly, how will this help me to improve?
- Or more to the point what happens if I install your OEE system and I don’t improve?
To me there are 4 levels of using an OEE system to improve:
1. Using the display to reduce reaction time on the line
- On a 55% line: typically 3-4% increase in efficiency based on reduced reaction time.
- This is achieved through setting up meaningful messages on the XL unit that teams react to in real time. E.g. If you regularly stop due to lack of raw materials have XL come up with a “low materials” alert prior to the machine stopping. Or perhaps program in your top 3-4 faults and have XL display a message when they occur to save precious time fault finding when the machine stops.
2. Using the reporting to carry out a structured review every 2 or 4 hours
- On a 55% line: The real area of improvement – between 3%-15% improvement through better allocation of resource during the shift
- Every 4 hours your team leader and line engineer review performance for the last 4 hours and identify what fixes need to be made to increase performance in the next 4 hours.
3. Using the reporting to carry out a structured review every 24 hours
- On a 55% line: When used with above – between 3%-10% improvement through better CI project allocation
- Review how effective the 4hr reviews were, what actions need to be picked up as a bigger project? Which teams perhaps need some coaching or support?
4. Using the reporting to carry out a structured review every week
a. On a 55% line: When used with above – between 3%-5% improvement ironing out persistent issues
When we have applied all 4 of these processes we’ve achieved OEE uplifts on 50-60% lines of between 6-8% in the first six months building to over 20% in 24 months.
In these instances the increase has been supported through a reasonable level of support and coaching (sometimes from us, sometimes done internally). The ‘secret’ to success here is focus; focus on being completely dedicated to creating the processes that will work for you and your teams and not accepting any distraction that pulls you from this.
To give you a sense for how we recommend you do this:
- Typically we would work on a pilot line to create a robust process and then rollout. To get the best results we create operational champions at the level of the Factory and Operations Manager – if those people know how to use a system I guarantee the rest of the site learn very quickly!
I think that it’s entirely reasonable to expect that you would get between 3%-5% OEE improvement with very little support from us at all just based through raising awareness to downtime. If you really want to get benefit from an OEE system, I would suggest building in the relevant management review processes to ensure that the system is used regularly.
We work in close partnership with the Operational Excellence practitioners at OptimumFX, and together, we've helped many manufacturers improve.
How can our OEE systems help you?
Why don't you have a look at our success with Coca-Cola Enterprises, and go through some of the results we've achieved to date? You can also request our ROI calculator and see for yourself the benefit that an OEE system can deliver in your specific manufacturing environment.