How to increase in overall equipment efficiency (OEE)

Sustainable increase in OEE – disruptions must not become routine

Sustainably increasing overall equipment efficiency (OEE) is a key lever for reducing production costs, increasing throughput and ensuring delivery capability. In many industrial companies, however, considerable potential remains untapped – due to creeping process deviations, unplanned downtimes, long set-up times or an inadequately coordinated production and logistics organization.

ifp consulting supports you in systematically improving overall equipment efficiency (OEE ) – in a practical, measurable way and together with your teams directly at the plant.

Overall equipment efficiency (OEE) as a control parameter

Overall equipment efficiency is determined by three factors: Availability, performance and quality. Losses in any of these areas have a direct impact on output, costs and delivery reliability. ifp consulting looks at OEE not as a pure key figure, but as an integrated control instrument to make the technical, organizational and logistical causes of efficiency losses transparent and to address them in a targeted manner.

Typical causes of loss in practice

Our projects reveal recurring patterns that limit equipment efficiency: unplanned downtimes, long set-up and adjustment times, micro-stops, reduced process speeds and quality losses during start-up or in series production. These so-called “six big losses” are often viewed in isolation – or not systematically recorded at all. This is precisely where our approach comes in: We make losses visible, evaluate them economically and derive specific measures from them.

How does system inefficiency arise and how do we support you in increasing OEE?

Partial, small deviations from the optimum condition add up and lead to long setup and downtimes, which in turn result in low availability of the systems. In order to be able to respond to customer requirements at short notice, capacity bottlenecks due to low plant utilization must be avoided at all costs. These are our recommendations for action for a rapid and sustainable increase in OEE:

This strategy creates a sustainable increase in OEE, which is anchored in a continuous improvement process.

ifp consulting combines analytical depth with a consistent focus on implementation. Depending on the initial situation, we design the path to greater plant efficiency in a modular and targeted manner. Among other things, we focus on OEE analyses and benchmarks, the structured recording of faults and quality problems, the optimization of set-up processes and the coordination of production control, logistics and maintenance. The active involvement of employees at the plant is always crucial in order to anchor sustainable improvements.

Fast effect and sustainable results

Many efficiency potentials can be realized within just a few weeks – for example through focused break-through projects or targeted set-up time optimizations. At the same time, we create the basis for long-term performance management of your systems with clear key figures, standards and responsibilities. The result is measurable improvements in throughput, costs, quality and production responsiveness.

Whitepaper Operational Excellence