Industries, especially in manufacturing, increasingly need to collect real-time production data to identify and remove the causes of inefficiency and improve productivity by reducing loss. In order to do this, you need to have a system that can collect and analyse production data fast and accurately. One that can help you identify the root causes of inefficiency and put them right in order to bring your actual productivity much closer to the theorectical one.
Productivity reality does not always live up to our expectations due to unforeseeable circumstances such as unavoidable scheduled production downtimes (due to absence of staff or ongoing maintenance) or unscheduled downtimes (due to unexpected system failure or malfunctioning) or increased number of product rejects. These problems are clearly caused by machine inefficiency that can be measured by using the OEE metrics (Overall Equipment Effectiveness). The conditions that cause these problems are called “equipment-related losses” (losses related to equipment).
There are 3 main measurable components that OEE uses in order to obtain the equipment-related losses:
- Availability: losses due to downtimes
- Quality: losses due to process defects
- Performance: losses due to slack productivity
These three components account for all the causes of production loss as well as unexpected downtimes that are not caused by failure (Set up, change of production, scheduled maintenance, meetings, holidays, strikes, etc.). Some machine malfunctions are alerted directly and automatically (alarms ). While others are left to the operator’s descretion to stop production in order to avoid further loss in downtimes due to unclassified causes.
Being efficient means having an information management system that is capable of collecting real-time data in order to calculate the Key Performance Indicator (KPI). This will allow you to assess your productivity index at any given time and the causes effecting the real capacity of your manufacturing processes.