Six Big Losses in OEE

The six big losses associated with OEE are important considerations when evaluating the performance of a manufacturing process. By understanding the causes of these losses and taking steps to address them, organizations can improve OEE and increase productivity, reduce waste, and lower costs.

Equipment Failure

Equipment failure or breakdown is a common cause of lost production time in manufacturing processes. To minimize equipment failure, organizations can take a variety of steps, including:

Implement preventative maintenance programs: Regular maintenance can help to prevent equipment failure by identifying and addressing potential issues before they become problems. This may involve conducting routine inspections, replacing worn parts, and cleaning and lubricating equipment.
Train operators to identify and address potential issues: Operator error is a common cause of equipment failure. By training operators to identify and address potential issues, organizations can help to prevent equipment failure. This may involve providing training on equipment operation and maintenance, as well as developing procedures for identifying and addressing potential issues.
Invest in high-quality equipment: Using high-quality equipment can help to reduce the frequency of equipment failure. This may involve investing in equipment from reputable manufacturers, or choosing equipment that has a proven track record of reliability.
Implement a robust spare parts program: Having a well-stocked inventory of spare parts can help to minimize equipment downtime in the event of a failure. This may involve maintaining a sufficient quantity of spare parts on-site, or having a system in place for quickly obtaining parts as needed.
Implement an equipment monitoring program: Implementing an equipment monitoring program can help to identify potential issues before they result in equipment failure. This may involve using sensors or other monitoring devices to track equipment performance, or regularly collecting and analyzing data on equipment operation.

Setup and Adjustment

Setup and adjustment time can be a significant contributor to lost production time in manufacturing processes, particularly in processes that involve frequent product changes. To minimize setup and adjustment time, organizations can take a variety of steps, including:

Implement quick-changeover techniques: Techniques such as single-minute exchange of dies (SMED) can help to significantly reduce setup and adjustment time. SMED involves identifying and eliminating waste in the setup process, and implementing methods for quickly and efficiently changing over equipment.
Invest in equipment that is easy to set up and adjust: Choosing equipment that is easy to set up and adjust can significantly reduce setup and adjustment time. This may involve looking for equipment with features such as quick-change tooling, automated setup procedures, or user-friendly control systems.
Train operators in setup and adjustment procedures: Providing training to operators on setup and adjustment procedures can help to reduce setup and adjustment time. This may involve providing training on the use of specific equipment, or developing standard operating procedures for setup and adjustment tasks.
Streamline the setup and adjustment process: Identifying and eliminating waste in the setup and adjustment process can help to minimize the time required. This may involve identifying and eliminating unnecessary steps, or automating tasks where possible.

Reduced Speed

Reduced speed, or the operation of equipment at a lower speed than its designed capacity, can be a significant contributor to lost production time. To minimize reduced speed, organizations can take a variety of steps, including:

Identify and address the root causes of reduced speed: In order to minimize reduced speed, it is important to identify the root causes of the issue. This may involve conducting assessments of equipment operation, analyzing data on performance, or working with operators to understand their experiences and perspectives.
Implement training and development programs for operators: Operator error is a common cause of reduced speed. By providing training and development programs for operators, organizations can help to improve operator performance and minimize reduced speed.
Conduct maintenance on equipment: Regular maintenance can help to ensure that equipment is operating at its designed capacity. This may involve replacing worn parts, cleaning and lubricating equipment, or conducting performance tests.
Invest in high-quality equipment: Using high-quality equipment can help to reduce the frequency of reduced speed. This may involve investing in equipment from reputable manufacturers, or choosing equipment that has a proven track record of reliability.
Streamline the production process: Identifying and eliminating waste in the production process can help to improve equipment performance and minimize reduced speed. This may involve streamlining material flow, reducing changeover time, or eliminating unnecessary steps in the process.

Quality Defects

Quality defects can be a significant contributor to lost production time, as they may result in rework or scrap. To minimize quality defects, organizations can take a variety of steps, including:

Implement quality control measures: Implementing quality control measures can help to identify and address issues before they result in defects. This may involve inspecting incoming materials, conducting in-process inspections, or implementing final inspection procedures.
Improve the production process: Identifying and addressing issues with the production process can help to minimize quality defects. This may involve streamlining the process, implementing process control measures, or making changes to equipment or materials.
Use higher-quality materials: Using higher-quality materials can help to reduce the frequency of defects. This may involve choosing materials from reputable suppliers, or specifying materials with known performance characteristics.
Train operators in quality control procedures: Providing training to operators on quality control procedures can help to ensure that they are following best practices and minimizing defects.
Implement a robust corrective action process: Having a process in place for identifying and addressing quality issues can help to minimize defects and prevent recurrences. This may involve conducting root cause analysis, implementing corrective actions, and tracking the effectiveness of the actions taken.

Startup and Shutdown

Startup and shutdown time can be a significant contributor to lost production time, particularly in processes that involve long production runs. To minimize startup and shutdown time, organizations can take a variety of steps, including:

Implement warm-up and cool-down procedures: Implementing warm-up and cool-down procedures can help to reduce the time required to start up and shut down equipment. This may involve following specific procedures for bringing equipment up to operating temperature or cooling it down before shutdown.
Invest in equipment that is easy to start up and shut down: Choosing equipment that is easy to start up and shut down can significantly reduce startup and shutdown time. This may involve looking for equipment with features such as automated startup and shutdown procedures, or user-friendly control systems.
Train operators in startup and shutdown procedures: Providing training to operators on startup and shutdown procedures can help to ensure that they are following best practices and minimizing downtime.
Streamline the startup and shutdown process: Identifying and eliminating waste in the startup and shutdown process can help to minimize the time required. This may involve identifying and eliminating unnecessary steps, or automating tasks where possible.
Conduct regular maintenance on equipment: Regular maintenance can help to ensure that equipment is ready to start up and shut down quickly and efficiently. This may involve cleaning and lubricating equipment, replacing worn parts, or conducting performance tests.

Minor Stops

Minor, micro or short stops, such as waiting for materials or tools, can be a significant contributor to lost production time. To minimize minor stops, organizations can take a variety of steps, including:

Implement just-in-time (JIT) inventory systems: JIT inventory systems can help to ensure that materials and tools are available when needed, reducing the time lost waiting for them. This may involve implementing a system for tracking and replenishing materials and tools, or using a vendor-managed inventory system.
Train operators in material and tool handling procedures: Providing training to operators on material and tool handling procedures can help to ensure that they are efficiently and effectively managing materials and tools, minimizing the time lost waiting for them.
Streamline material and tool flow: Identifying and eliminating waste in the flow of materials and tools can help to minimize the time lost waiting for them. This may involve implementing lean principles such as one-piece flow or kanban systems, or automating tasks where possible.
Invest in equipment that is efficient at handling materials and tools: Choosing equipment that is efficient at handling materials and tools can help to minimize the time lost waiting for them. This may involve looking for equipment with features such as automated material handling systems or quick-change tooling.Implement a robust corrective action process: Having a process in place for identifying and addressing issues with materials and tools can help to minimize minor stops and prevent recurrences. This may involve conducting root cause analysis, implementing corrective actions, and tracking the effectiveness of the actions taken.

Improving OEE requires a systematic approach that involves identifying and addressing the root causes of the six big losses. This may involve implementing new processes, training operators, conducting maintenance, or investing in new equipment. It is also important to continuously monitor and track OEE to identify areas for improvement and to ensure that progress is being made.

PlantRun is designed to give you accurate information on each of the Six Big losses allowing you to target your most largest losses for improvement.