Implementation Of Overall Equipment Effectiveness Research Articles

Optimizing Auto Manufacturing: A Holistic Approach Integrating Overall Equipment Effectiveness for Enhanced Efficiency and Sustainability

In the face of pandemic-induced emergencies and unpredictable natural disasters, industries are compelled to implement rescue plans to mitigate unexpected risks. In this context, Overall Equipment Effectiveness (OEE) is considered as a key metric, followed by sustainability efforts to manage unforeseen risks, encompassing social, environmental, and economic aspects. OEE is considered as a lean tool to determine the efficiency of equipment or processes on par with the world class OEE standard, i.e., 85%. Performance, Availability and Quality as three main drivers of OEE. This research study explores the implementation of OEE in conjunction with sustainability principles in an auto sector manufacturing firm, aiming to enhance operational efficiency and sustainability practices. The research involves a 12-week initial session from April to June 2022, followed by an analysis of July to September 2022, resulting in an impressive OEE value of 48%. Notable improvements in Availability (89.75%), Performance (72.68%), and Quality (73.82%) contribute significantly. The analysis reveals enhancements in scrap rework (17%), training (16%), maintenance (13%), material availability (12%), and production capability (11%). Achievements include improvements in green profile (25%), health and safety (20%), and energy efficiency (25%), along with reductions in carbon dioxide emissions (21%), waste management (17%), and scrap (15%). This research underscores the commitment of the case study industry to sustainable development and economic growth, showcasing significant enhancements in product quality and efficiency. The integration of sustainability principles into OEE initiatives is pivotal for modern industrial optimization. The study results highlight the profound significance of this synergistic relationship, particularly within the blending section, driving substantial positive outcomes in manufacturing processes and operational excellence. The implementation of sustainability efforts not only mitigates risks and fosters growth for automotive manufacturers but also yields environmental benefits. Based on findings of this study, a roadmap for automotive manufacturers is devised to achieve robust OEE while concurrently reaping economic and environmental rewards by employing sustainability principles.

Implementation of overall equipment effectiveness and financial performance assessment framework in a semiconductor manufacturing facility: A case study

Implementation of overall equipment effectiveness and financial performance assessment framework in a semiconductor manufacturing facility: A case study

Implementation of Overall Equipment Effectiveness (OEE) in Textile Manufacturing Company

Implementation of Overall Equipment Effectiveness (OEE) in Textile Manufacturing Company

A Systmatic Literature Review

Overall equipment effectiveness (OEE) is an approach used to measure the productivity of equipment or machines. The aim of this paper is to identify review and analyze the OEE approach. More specific knowledge about OEE has grown rapidly. Much research on OEE is carried out in various industries to measure the productivity of equipment or machines. This paper involves a review study of 30 papers related to OEE implementation in various industries. This paper contains the results of many different aspects. These aspects include focus is an industry. Focus number of distribution by country and focus year of publication. This paper is useful for all types of industrial sectors to find solutions to problems with equipment or machine performance. This paper also provides an advantage for future researchers to add insight and reference for OEE-related studies in various industries.

Interpretive structural modelling to evaluate the key barriers inhibiting successful implementation of overall equipment effectiveness

Interpretive structural modelling to evaluate the key barriers inhibiting successful implementation of overall equipment effectiveness

Real-Time OEE for Industry 4.0 Learning and Practice Training

Overall Equipment Effectiveness (OEE) is a well-established KPI metrics to measure the equipment effectiveness. OEE has been widely used for many industries as a quantitative tool for measuring of productivity. Singapore institute of manufacturing technology (SIMTech) designs the “Real-Time OEE for Industry 4.0 implementation and OEE improvement” training program using Learn-Practice-Implement (LPI) model. The learner could practice OEE implementation in Model Factory@SIMTech before actual implementation at customer site. This paper presents the training methodology and the benefit of the training program.

Analysis and directions of OEE and its integration with different strategic tools

The manufacturing industries are among the focused industries of any country according to their contribution to nations’ economies. Therefore, the appropriate utilization of all manufacturing/processing equipment is a high priority. The problem is the complexity to keep all the activities, operations, and use of equipment in synchronization with the reduction of all possible losses and defects. Such losses are becoming the real cause of the investment in the maintenance section of the industrial units. The different versions of established concepts define ‘Maintenance’ as ‘repair of the equipment,’ but this concept covers old and limited dimensions. Therefore, this notion relates the maintenance strategies only as a function of preventive maintenance, predictive maintenance and corrective maintenance. At the basic level of OEE implementation, various process industries of the country are yet unaware of the potential benefits of this strategic tool. The quality and performance-enhancing approaches are being developed based on time management and production loss analysis to get the optimum output from available resources. This study is to mark all the critical strategies associated with sustainable performance and to trace all possible drawbacks while measuring effectiveness through OEE (Overall Equipment Effectiveness). OEE is a tool of Total Productive Maintenance (TPM) without whom the effective utilization of resources is a difficult task. OEE supports the entire perspective on effectiveness uniquely and logically but also improves the life span of the machinery through improvements and monitoring in the maintenance operations and activities. This paper aims to identify the role of different strategies associated with OEE for unceasable production and optimum use of resources. This paper arranges the literature in an organized way and assists to find promising decisions to implement OEE with integrated concepts.

An integrated OEE framework for structured productivity improvement in a semiconductor manufacturing facility

PurposeThe purpose of this paper is to introduce a practical integrated overall equipment effectiveness (OEE) framework that encompasses the core characteristics of OEE.Design/methodology/approachThe paper reviewed the backgrounds of OEE and improvement frameworks and explored the limitations. An integrated OEE framework was developed by synergizing the strengths of OEE and improvement frameworks to complement the shortcomings. This new framework underlies the OEE concepts and provides structural improvement steps. It was applied to systematically assist and guide OEE practitioners in a case study.FindingsThe review of OEE literature found that there is a lack of improvement frameworks with systematic steps specifically developed for OEE implementation. Conversely, a review on improvement frameworks of different methodologies revealed that they do not fully capitalize on the use of performance measures as benchmarks and improvement drivers. An integrated framework that incorporated the advantages of both OEE and conventional improvement frameworks was developed and validated through a case study over a period of 38 weeks. The OEE performance before the improvements was low (73.4 percent) due to high availability losses (76.5 percent). Both OEE and availability achieved the target of 76.5 percent and 80 percent, respectively, after using the framework for improvements.Research limitations/implicationsThe reviewed papers represent a sample of papers present in the literature and were selected based on relevancy. A greater number of papers incorporated into the literature review would certainly bring out a more comprehensive study.Practical implicationsThe proposed integrated OEE framework provides OEE practitioners with systematic directions and steps combined with benchmarking and loss prioritization features for effective improvement efforts. In addition, it provides overview for the practitioners to make better decisions in project management. This helps address the common issues of practitioners not sure of what the next improvement step is. A case study using the proposed framework at a semiconductor company had successfully achieved the OEE benchmarks and set target for conversion time.Originality/valueThis paper provides a new integrated OEE framework offering a systematic approach toward implementing OEE improvements.

Novel availability and performance ratio for internal transportation and manufacturing processes in job shop company

Purpose: Purpose of this study includes the quantification of the impact of transportation efficiency onto the workstations the transportation serves in term of throughput and total lead time elapsed by product. Besides, it aims to synchronize the capacity available among workstations throughout a production line by studying the upper limit of throughput could be afforded by each workstation as well as their connection with each other. This study is also done on the purpose of promoting fulfillment of customer demand at shorter delivery time and minimal equipment utilization. Investigation on implementation of Overall Equipment Effectiveness (OEE) in an aerospace part-manufacturing company is studied to track out the potential opportunities to be improved.Design/methodology/approach: Site observation is conducted on all the five manufacturing workstations in the aforementioned aerospace part manufacturing company. Time data of both automated processes and manual processes are collected and they are used to construct simulation model. From that, various scenarios of transportation efficiency are simulated in Experiment 1. In addition, Experiment 2 is also set to examine the maximum capacity of each workstation. All of these are to highlight the relationship between workstation and processes and to verify the condition of imbalanced capacity among workstations in the company. In short, this has necessitated the integration of workstation and transportation activities within the company. These are followed by proposal of measures to quantify the wastes identified.Findings: The paper finds that implementation of OEE alone does not consider the reasonability of customer demand fulfillment. The results show that both transportation efficiency and imbalanced capacity throughout production system are not emphasized by OEE implementation in the case company. Therefore, responsibility of all workstations and transportation process in delivering demand on time are quantified. Transportation process which serves as the connectors of manufacturing processes is quantified and monitored by proposed Transportation Measure (TM) whereas workstations are measured using novel availability and performance ratio.Research limitations/implications: Future research should be conducted to examine the impact of other station within a company such as warehouse and logistic department to the performance of equipment and materials in manufacturing workstation. Besides, the material availability as well as the skills or performance of man power could be further incorporated into the measures to consider all the entities involved in manufacturing processes.Practical implications: The proposed availability and performance ratio for both transportation and manufacturing processes, which are related to each other, help in promoting better effectiveness of production system in terms of production amount and lead time. Besides, reasonable utilization equipment and minimal consumption of material are incorporated in the measures to promote Lean way in fulfilling customer demand. The effectiveness of entire production line is examined as a unity with joint responsibility under varying transportation efficiency and cycle time of each workstation. Both measures could be implemented together to optimize the production system and quantify the hidden wastes which are neglected in the OEE implementation.Originality/value: The novel availability and performance ratio are proposed to consider customer demand, historical equipment utilization and Takt time of each workstation to examine the possibility and reasonability of demand fulfillment. This prevents both over-processing and overproduction issues which are invisible in OEE. Furthermore, delay propagation throughout production system and interrelationship between processes are quantified under transportation measure. Other novelty of the paper is that it monitors the waiting time and lead time spent in each workstation at the same time considering utilization of workstation. The proposed Transportation Measure (TM) aims to reduce the queue length and waiting time at destination workstation at minimal utilization of forklift. It also promotes less capacity investment in transportation and prioritizes its scheduling according to urgency of destination workstation.

Interpretive Structural Modeling to evaluate the key barriers inhibiting successful implementation of Overall Equipment Effectiveness

The scope of study is to cover the critical and significant barriers in implementation of overall equipment effectiveness (OEE) through interpretive structural modelling (ISM). Based on a common proverb "If we can't measure it, we can't improve it", ISM is the competent approach to measure the significance of its various variables (barriers), their hierarchy and interdependency on each other. The barriers affecting OEE implementation may vary as per industrial sectors, but the goal would remain the same, i.e., to embellish the performance. Fourteen critical barriers of OEE implementation were analysed with the directions and guidelines of industrial and academic experts. In addition, ISM model is proposed for the key barriers. ISM may be used to understand the relationship between barriers. Once the behavioural pattern of barriers is determined through ISM, it is easy to predict the issues related to equipment's maintenance and efficiency over a specific phase of time.

Justification of Overall Equipment Effectiveness (OEE) in Indian Sugar mill industry for attaining core excellence

The role of this study is to expand an understanding of Overall Equipment Effectiveness (OEE) proposals towards developing central capabilities in Indian sugar mill industries. The authors have decisively examined the implications of OEE implementation in the sugar mill sector. The study discloses that management and leadership, with their honest involvement towards execution of Japanese’s maintenance practices, can appreciably add to accumulate the core competencies and sustainability. The study highlights that OEE initiatives outscore traditional maintenance practices towards improving process performance (PP). Attentive OEE implementation over a reasonable time period can extensively increase the consciousness of central capabilities in PP. The study has been carried out to establish the assistance of OEE proposals for achieving core competencies in process industries. Though, sector-wise execution of the plan for all process industries can also be achieved to evaluate the contributions of OEE in the industrial sectors. The plan of the study is to spot the impact of key OEE proposals and dimensions on managerial performance. The paper emphasizes the need to bring disciplined organizational changes in launching maintenance improvement activities for approving the enhancements in the performance of the industry. In today’s highly dynamic and rapidly changing environment, the global competition among organizations has guided the maintenance activities to précised demands in the manufacturing organization.

Application of OEE for productivity analysis: a case study of a production line from the pulp and paper industry

The overall equipment effectiveness (OEE) is an indicator used in the management and continuous improvement of production systems, and is useful in identifying losses, thus reducing production costs. By analyzing the results of this indicator, the operation manager must make decisions to eliminate or reduce losses in the process. This study investigated the application of the OEE indicator in one production line in the pulp and paper industry. The implementation of OEE was performed in stages with a detailed analysis of the indicators that compose the OEE (quality, performance, and availability) to identify possible improvements. Thus, actions were implemented to improve the OEE quality index. This study provided important information that enabled the operation manager to diagnose and minimize the occurrence of failures and losses, which is often hidden and unknown to those involved in the production system.

Overall equipment effectiveness (OEE): a review and development of an integrated improvement framework

The paper reviews the background of OEE and various improvement frameworks and explores their limitations. The review found that there is a lack of improvement frameworks with systematic steps specifically developed for OEE implementation. In addition, it was found that improvement frameworks of different methodologies do not fully capitalise on the use of performance measures as benchmarks and improvement drivers although they provide structured improvement steps/guidelines. These findings show there is a need for a new integrated OEE improvement framework that incorporates the advantages of both OEE and improvement frameworks. By encompassing the core characteristics of OEE and synergising the strengths of improvement frameworks, the new framework will provide OEE practitioners a systematic guidance in carrying out improvement implementation. It will also provide overall directions on how to carry out OEE improvements and allow the practitioners to make better decisions regarding project management.

Practical Framework: Implementing OEE Method in Manufacturing Process Environment

Manufacturing process environment requires reliable machineries in order to be able to satisfy the market demand. Ideally, a reliable machine is expected to be operated and produce a quality product at its maximum designed capability. However, due to some reason, the machine usually unable to achieved the desired performance. Since the performance will affect the productivity of the system, a measurement technique should be applied. Overall Equipment Effectiveness (OEE) is a good method to measure the performance of the machine. The reliable result produced from OEE can then be used to propose a suitable corrective action. There are a lot of published paper mentioned about the purpose and benefit of OEE that covers what and why factors. However, the how factor not yet been revealed especially the implementation of OEE in manufacturing process environment. Thus, this paper presents a practical framework to implement OEE and a case study has been discussed to explain in detail each steps proposed. The proposed framework is beneficial to the engineer especially the beginner to start measure their machine performance and later improve the performance of the machine.

An analysis of managerial factors affecting the implementation and use of overall equipment effectiveness

To ensure manufacturing organisations remain competitive, most of them are turning to total productive maintenance (TPM) and lean manufacturing to ensure seamless operations. Overall equipment effectiveness (OEE) is the foundation of these two business improvement strategies as it tackles the underlying losses that impede equipment efficiency. This study presents the prevalence of managerial issues related to the implementation and use of OEE in the manufacturing industry. To do this, five hypotheses and four research questions were formulated and tested using a combination of descriptive statistics and cross-tabulation, chi-square, analysis of variance, Tukey’s pairwise comparison, Z-test and correlation tests. Data were collected through a survey questionnaire responded by 139 manufacturing organisations worldwide. The results establish, among other ‘soft’ aspects, the linkage of the OEE implementation with that of TPM and lean manufacturing, and the drivers, most critical factors, barriers and the role of management in its implementation. The study also identifies how manufacturing organisations employ the information provided by OEE and how the data for its computation are collected. This study supports the very limited empirical research on the implementation and use of OEE. Thus, this research provides organisations, and their managers, with a better understanding of different factors that affect the successful deployment and management of this highly used measure in industry.

An Exploratory Study of OEE Implementation in Indian Manufacturing Companies

Globally, the implementation of Overall equipment effectiveness (OEE) has proven to be highly effective in improving availability, performance rate and quality rate while reducing unscheduled breakdown and wastage that stems from the equipment. This paper investigates the present status and future scope of OEE metrics in Indian manufacturing companies through an extensive survey. In this survey, opinions of Production and Maintenance Managers have been analyzed statistically to explore the relationship between factors, perspective of OEE and potential use of OEE metrics. Although the sample has been divers in terms of product, process type, size, and geographic location of the companies, they are enforced to implement improvement techniques such as OEE metrics to improve performance. The findings reveal that OEE metrics has huge potential and scope to improve performance. Responses indicate that Indian companies are aware of OEE but they are not utilizing full potential of OEE metrics.

Consideration of demand rate in overall equipment effetiveness (OE) on equipment with constant process time

Purpose: The paper is primarily done on the purpose of introducing new concept in defining the Overall Equipment Effectiveness (OEE) with the consideration of both machine utilization and customer demand requested. Previous literature concerning the limitation and difficulty of OEE implementation has been investigated in order to track out the potential opportunities to be improved, since the OEE has been widely accepted by most of the industries regardless their manufacturing environment. Design/methodology/approach: The paper is conducting the study based on literature review and the computerized data collection. In details, the novel definition and method of processing the computerized data are all interpreted based on similar studies performed by others and supported by related journals in proving the validation of the output. Over the things, the computerized data are the product amount and total time elapsed on each production which is automatically recorded by the system at the manufacturing site. Findings: The finding of this paper is firstly the exposure and emphasis of limitation exists in current implementation of OEE, which showing that high utilization of the machine is encouraged regardless of the customer demand and is having conflict with the inventory handling cost. This is certainly obvious with overproduction issue especially during low customer demand period. The second limitation in general implementation of OEE is the difficulty in obtaining the ideal cycle time, especially those equipments with constant process time. The section of this paper afterward comes out with the proposed solution in fixing this problem through the definition of performance ratio and then usage of this definition in measuring the machine utilization from time to time. Before this, the time available for the production is calculated incorporating the availability of OEE, which is then used to get the Takt time. Research limitations/implications: Future research should be conducted to test the possibility and to verify the definition of such performance ratio including Takt time on those processes of which its operating time is possibly to be reduced, especially those are not constant and fixed. This piece of research is temporarily done on the process where its operating time is constant from time to time and there is no ideal cycle time possible. Practical implications: The awareness of the overproduction should be emphasized and raised in the intention of pursuing higher OEE value. As the definition proposed such, the process with constant cycle time could even be defined in different performance ratio from time to time regarding to the customer demands and corresponding production rate. These two variables can be adjusted and balanced to increase the OEE value through optimization of average cycle time. Over this, optimization of average cycle time on equipment with constant operating time can be achieved through the optimization of loading number per each processing. Originality/value: The novelty of the paper is the inclusion of customer demand in obtaining OEE value of any particular equipment. Besides that, the equipment without ideal cycle time, which means those processes carried out in constant cycle time are possibly to be evaluated with performance ratio. As consequence of that, the machine utilization and capability used could be quantified and visualized using the performance ratio data of the OEE proposed.