Plants with long set-up and downtimes lead to high costs with low production. Increasing plant efficiency is a prerequisite for implementing lean processes.
Low plant efficiencies occur primarily in plants operated over the long term. Small changes that lead away from the optimal setup process or short-lived disruptions are transferred into the routine by the plant operators and are thus not perceived as a serious cost factor.
Equipment is operated below maximum speed because the machine has been inadequately maintained and cannot withstand the load, or because any control mechanisms are not designed for the proper speed of the equipment. Quality problems are often due to improvable processes or insufficient maintenance.
However, even completely new plants can have low efficiency if the customer’s needs cannot be properly met or if the logistics and production concepts are not coordinated.