Improve OEE By Managing These 3 Potent Aspects

The global gold standard for measuring production efficiency across industries is Overall Equipment Effectiveness (OEE). OEE is the percentage of total operating time a machine works at maximum capacity and produces the best output. It is based on lean manufacturing practices. The product of availability, performance, and quality rates yields OEE. If your company’s availability, performance, and quality rates are high, you definitely have a good OEE. Here are some of the equipment losses that will reduce your OEE percentage output and how IoT can manage those aspects.

Manage Availability

The number one adversary of operational efficiency is unplanned downtime caused by equipment or part malfunctions, and also material shortages.This is the type of production that costs the most to companies or manufacturers. Predictive maintenance powered by IoT Envion is great for managing unplanned downtime. Different operational data like temperature, motor vibration, and currents can be examined using machine learning algorithms to identify common symptoms preceding historical failures.

Another way to increase your availability is by managing planned downtime. This is a part of equipment setup, changeovers, inspections, and maintenance. While planned downtime may seem to be unavoidable, IoT technology can assist manufactures in controlling and minimizing it. Unlike preventive maintenance, the IoT sensor collects data that gives insight for predictive maintenance – based on actual asset conditions rather than a hypothetical repeating schedule. IoT sensors' automated data also reduces the need for manual inspections, which could cause the production line to stop.

Manage Performance

Reduced speed is when your equipment slows down the production cycles and reduces overall productivity. IoT with environmental sensors can provide a drill-down analysis to determine the underlying reasons for the loss and the solution for it. Operators also can be alerted when assets are running at sub-optimal speeds using vibration sensors.

Another way to increase performance rate is by managing minor stops. It is the condition when machines stop for a short period of time. It happens with easily resolved issues like material jams, misfeeds, material jams, or misaligned parts. These often cause a snowball effect in the long term. In this context, IoT sensors can accurately record these small stops. This will help operators identify where the minor stops happen and the issues can be eliminated with corrective procedures.

Mange Quality

Startup losses happen between the stabilization state of equipment and warmup. Although this is part of equipment operations, there is certainly room for improvement. By leveraging sensor data, manufacturers can identify which conditions and cycles generate more defects and how it can be solved.

The frequency of process defects also impacts your OEE quality rate. It happens when the products fail to fulfill required quality standards during steady-state production, resulting in scraps and rework. Aside from equipment-related concerns, changes in shop-floor environmental conditions can have a substantial impact on the consistency and quality of raw materials and end-products, resulting in process errors.

One quick solution for that is to connect your manufacturing line with an IoT-based OEE solution that can monitor the equipment and environmental variables. Telkomsel will launch such a solution this year. Stay updated with our latest releases by following our instagram and linked-in blog.

Maintaining a high OEE level is critical to your company's productivity and sustainability. Telkomsel IoT is here to help.