Manufacturing quality isn’t just about the end product; it’s also about the processes that create it.
That’s where Overall Equipment Effectiveness (OEE) comes into play. OEE is a recognised standard for measuring manufacturing productivity, including quality.
By improving your OEE score with POET, you can ensure that your equipment is as productive as possible, leading to higher-quality products.
However, neglecting OEE can lead to significant inefficiencies, risking your financial performance and putting your business at risk. In a world where a product recall or customer complaint can quickly escalate, your production process is the backbone of your product quality.
Don’t let preventable inefficiencies become the Achilles’ heel of your business.
Understanding OEE
At its core, OEE assesses how effectively a manufacturing operation utilises its resources. OEE is broken down into three main components: Availability, Performance, and Quality.
- Availability refers to the time that the equipment is ready to run as a percentage of the planned production time.
- Performance accounts for the rate at which products are manufactured against the maximum possible speed.
- Quality measures the proportion of good parts to the total parts produced.
OEE is calculated by multiplying these three components. A score of 100% would mean that a plant produces only good parts, as fast as possible, without any stop time. 100% OEE is, however, unachievable. What we often find is that companies are operating between 40-60% OEE, and using POET they can rapidly achieve 75-85%. This is game changing for profitability and growth.
Contact POET Systems today to learn how we can help you achieve substantial improvements in profitability and growth. Let’s make your OEE journey a success!
Improving Availability
Think of your manufacturing process as a relay race, where availability is the speed and efficiency of the first runner.
Just as a swift and smooth start is crucial in a relay race, ensuring equipment is always available and in top condition is your starting block for boosting OEE.
Downtime, like a slow start, can hinder the entire race, impacting your manufacturing quality and output. To improve your “first runner’s” performance, consider:
- Implement preventive maintenance schedules to avoid unexpected breakdowns.
- Train staff to handle quick changeovers and setups to minimise transition time.
- Use automated systems to predict and prevent potential equipment failures.
Enhancing Performance
Consider your manufacturing process as having similarities to a finely-tuned orchestra, where each machine’s optimal speed is like an instrumentalist playing at peak performance—a key element for a harmonious symphony.
A machine running at its optimal speed will produce more, which is crucial for meeting production demands without compromising quality. To enhance performance, you might find that your manufacturing business needs to:
- Streamline your workflow to eliminate bottlenecks.
- Regularly calibrate and maintain equipment to ensure it operates at full capacity.
- Measure and analyse performance data to identify and address inefficiencies.
Elevating Quality
Think of ‘Quality’ as the foundation of your manufacturing process, much like the roots are to a thriving tree.
Enhancing quality ensures your product grows strong and healthy, with fewer defects and waste, much like nourished roots lead to better fruit. Foster your “quality roots” with these steps:
- Setting clear quality standards and ensuring proper training of staff to meet them.
- Implementing real-time monitoring systems to catch inefficiencies or defects early on.
- Engage in continuous improvement practices to reduce waste and defects.
By integrating POET into your manufacturing operations, you unlock a suite of tools designed to improve availability, enhance performance, and elevate product quality, leading to a significant boost in your Overall Equipment Effectiveness (OEE).
Deep Dive into Quality Improvement
Quality in the context of OEE speaks to the essence of manufacturing excellence.
Enhancing this involves a meticulous approach to every stage of the manufacturing process:
- Root Cause Analysis: Implement systemic methods to find and address the core issue behind quality failures, preventing recurrence.
- Standardisation: Develop and maintain standard operating procedures (SOPs) for tasks to ensure consistency and reliability in production outputs.
- Employee Involvement: Foster a culture where every employee feels responsible for quality, encouraging them to contribute ideas for improvement.
- Statistical Process Control (SPC): Use SPC techniques to monitor production processes and detect variances early before they lead to defects.
Ready to elevate your manufacturing quality? Embrace our suite of tools and strategies with POET. Dive into Root Cause Analysis, standardise your processes, involve your team, and utilise Statistical Process Control. Contact POET Systems today to start your journey.
Beyond Manufacturing: The Wider Impact of High OEE Scores
High Overall Equipment Effectiveness (OEE) scores go beyond just enhancing manufacturing operations; they influence every layer of the business and reach out into the wider business ecosystem, creating a ripple effect of benefits.
Here’s how high OEE scores can make a broader impact:
Economic Benefits
Cost Reduction: High OEE scores typically mean that a manufacturing operation is running smoothly and efficiently, cutting down on wastes like excessive use of materials or energy.
This efficiency leads directly to cost savings, particularly by reducing the need to spend on overtime labour, excess materials, and energy consumption.
Increased Production Capacity: Efficient operations mean more can be produced in less time, potentially leading to increased market share and revenue without the need for new equipment or additional overhead expenditures.
This is crucial in industries where meeting market demands in a timely manner can dictate the success of the business.
Customer Satisfaction and Competition
Improved Delivery Times: Increased efficiency means that manufacturing processes are less likely to face delays, which in turn leads to faster delivery times for customers.
This reliability can significantly enhance customer satisfaction and lead to repeat business.
Enhanced Product Quality: With lower defect rates and higher consistency in production, high OEE scores often result in better product quality.
Superior products strengthen customer trust and can position a company as a leading brand in competitive markets.
Brand Reputation
Market Perception: Companies known for efficient operations and high-quality products are generally viewed more favourably in the marketplace.
A reputation for reliability and quality can make a significant difference in highly competitive sectors.
ESG & Corporate Responsibility: Efficient processes that use less energy and create less waste reflect well on a company’s commitment to sustainability.
Responsible corporate behaviour helps build a positive brand image and can appeal to environmentally conscious consumers and stakeholders.
Regulatory Compliance and Advantages: Efficient processes that contribute to sustainability goals can also help a company meet increasingly stringent environmental regulations more easily.
This can provide a competitive edge by pre-empting compliance costs that competitors may not yet be prepared for.
Workforce Morale and Safety
Employee Satisfaction: Efficient and predictable workflows contribute to a safer and more satisfying work environment. High OEE indicates that equipment failures and unexpected downtime, which can be stressful and hazardous for workers, are minimised.
Safety Enhancements: Reduced equipment failures and malfunctions mean fewer workplace accidents, which not only protects employees but also reduces costs associated with workplace injuries and insurance claims.
Increase Your OEE and Manufacturing Quality With POET
Enhancing the quality of your manufacturing processes directly correlates to a comprehensive understanding and application of Overall Equipment Effectiveness (OEE).
The first step is to assess your current OEE score and use it as a baseline. From there, you can implement the strategies outlined here to foster continuous improvement.
Let’s work together to transform your manufacturing processes from good to exceptional! Contact POET Systems today to find out how we can help you progress.
