An unplanned stop in OEE refers to any unexpected event that causes production to halt, significantly impacting the availability of equipment.
These interruptions directly reduce OEE scores, as they lead to downtimes that disrupt manufacturing efficiency.
Unplanned stops wreak havoc on schedules, productivity, and ultimately, the bottom line.
Impact on Overall Equipment Effectiveness
Unplanned stops negatively affect Overall Equipment Effectiveness by reducing equipment availability.
When machines stop unexpectedly, production lines cannot maintain their planned production cycles.
Each minute of downtime translates to a loss in productive time, which diminishes the OEE score.
For instance, a mechanical failure lasting 30 minutes not only disrupts the workflow but also requires additional time for diagnostics and repairs, further increasing downtime.
The more frequent and prolonged these unplanned stops, the lower the OEE score.
Common Causes of Unplanned Stops
Unplanned stops originate from various sources, disrupting production unexpectedly.
Mechanical Failures
Broken parts or malfunctioning equipment halt operations until repairs are complete.
Electrical Issues
Power outages or electrical faults cause sudden production stops, requiring troubleshooting to resume.
Human Errors
Operator mistakes, such as incorrect machine settings or procedural deviations, lead to unplanned downtimes.
Maintenance Delays
Postponed or inadequate maintenance increases the likelihood of unexpected failures.
Supply Chain Disruptions
Shortages or delays in raw materials halt production lines until resolved.
Measuring Unplanned Stops
Accurately measuring unplanned stops ensures precise identification of inefficiencies.
Misidentification of these stops leads to incorrect troubleshooting efforts.
Data from accurate measurements helps define patterns, highlight recurring problems, and prioritise corrective actions.
For example, if recurrent mechanical failures remain undetected due to inaccurate data, maintenance efforts will misaddress the root causes.
Properly recorded data also aids in verifying improvements after implementing changes, ensuring the effectiveness of corrective measures.
Strategies to Minimize Unplanned Stops
Preventive maintenance plays a crucial role in reducing unplanned stops.
Regularly scheduled inspections and servicing prevent breakdowns by addressing potential issues before they cause equipment failure.
We recommend the following practices to improve preventive maintenance:
Regular Equipment Inspections
Check for signs of wear, lubrication levels, and alignment to catch problems early.
Scheduled Servicing
Follow manufacturer guidelines for maintenance intervals and document all servicing activities.
Predictive Maintenance Technologies
Use sensors and software to predict failures before they occur, allowing for timely intervention.
Regular Training Sessions
Conduct regular workshops focusing on equipment handling, troubleshooting, and safety procedures.
Clear Operational Protocols
Provide detailed, easy-to-follow guidelines for all operational tasks to minimise human error.
Awareness Campaigns
Promote the importance of maintaining equipment and following protocols through visual aids, meetings, and digital communication.
