Your 10 week plan to increase your OEE by 6% -30%

Your 10 week plan to increase OEE by 6% - 30%

10 week plan - What is OEE?

For plastics manufacturers, efficiency is key to achieving profitability and efficiency is the difference between thriving and surviving. One of the most powerful ways to measure and improve efficiency is through Overall Equipment Effectiveness (OEE). We’ve used a wide spread on what can be achieved to allow for the nuances of each factory set-up.  

OEE provides a clear snapshot of how well your production lines are performing and pinpoints the areas holding you back. An OEE score of 85% is considered “world-class” — yet many manufacturers fall well below this benchmark, leaving untapped profit and capacity on the table. 

The good news? With a focused action plan, it’s possible to increase your OEE by anywhere between 6% and 30%. This 10-week roadmap shows you how to make consistent improvements that deliver real results. 

Week 1: Assess your Current OEE and Identify Key Areas for Improvement

To begin, you must first assess where you are right now, how your operations stand today. A detailed OEE analysis provides valuable insights into your current performance and helps identify areas of waste, inefficiencies, and bottlenecks. This data acts as baseline for all your improvement efforts. 

Action Steps: 

  1. Collect Data: Gather baseline OEE data from your machines, lines, or entire facility. Tools like Manufacturing Execution Systems (MES) can track real-time production data and give you a comprehensive picture of your equipment’s effectiveness. 
  2. Analyse Losses: Look at the three components of OEE: Availability, Performance, and Quality. Are your machines experiencing a lot of downtime? Is there excessive waste? Or are you not operating at optimal speeds? 

Week 2: Focus on Reducing Downtime

Unplanned downtime is the number one killer when it comes to OEE. Whether it’s unplanned maintenance, operator error, or slow start-ups, reducing downtime is the first step in achieving a significant OEE improvement. 

Action Steps: 

  1. Predictive Maintenance: Implement a predictive maintenance strategy that uses sensors and data analytics to predict when machines need maintenance before breakdowns occur. This reduces unplanned downtime and keeps machines running smoothly. 
  2. Standardise Operating Procedures: Make sure all workers follow standard procedures for machine setup, operation, and shut down to reduce unnecessary downtime. 

Week 3: Optimise Equipment Performance

Improving equipment performance is essential for boosting OEE. Running below rated speed wastes valuable production time. Performance efficiency refers to how well a machine performs relative to its maximum speed. If you’re running your machines slower than their rated speed, you’re wasting valuable time and resources. 

Action Steps: 

  1. Identify Performance Gaps: Use the data from your OEE assessment to identify areas where equipment performance is lagging. Are there machines that should be running faster? Are there operators who can be trained to use the equipment more effectively? 
  2. Set Performance Targets: Work with your team to set performance targets for each piece of equipment. Regularly monitor progress to ensure you’re on track. 

Week 4: Improve Product Quality

Quality is another key component of OEE. The fewer defects you have, the higher your OEE will be. Addressing quality issues will help reduce waste, rework, and scrap—directly impacting your bottom line. 

Action Steps: 

  1. Implement Root Cause Analysis: Whenever a quality defect occurs, conduct a root cause analysis to identify the underlying issue. Is it a machine problem? Operator error? Material quality? 
  2. Quality Control Systems: Integrate quality control systems at each stage of production to catch defects early before they become bigger issues. 

Week 5: Enhance Operator Efficiency

Human error can play a significant role in reducing OEE, and operator efficiency is often an overlooked area. Increasing operator efficiency can have a significant impact on production speed and quality. 

Action Steps: 

  1. Training and Skill Development: Invest in comprehensive operator training to ensure that everyone knows how to operate the machines properly and efficiently. 
  2. Paperless Systems: Implement a paperless system for work instructions, inventory management, and machine settings. This can save time, reduce mistakes, and improve overall workflow. 

Week 6: Focus on Lean Manufacturing Principles

Implementing lean manufacturing principles can help eliminate waste, improve process flows, and increase overall productivity, all of which are directly tied to OEE. 

Action Steps: 

  1. Identify and Eliminate Waste: Look for waste in the form of excessive movement, unneeded materials, or inefficient processes, and work to eliminate it. 
  2. Implement 5S: The 5S methodology (Sort, Set in Order, Shine, Standardise, Sustain) helps create a more organised and efficient workspace, which can significantly improve OEE. 

Week 7: Automate Data Collection

Automating data collection allows you to track OEE metrics in real-time, enabling quick reactions and more effective decision-making. 

Action Steps: 

  1. Use Real-Time Monitoring Systems: Install monitoring systems to track production performance, downtime, and quality data automatically. 
  2. Create Dashboards: Develop visual dashboards that make it easy for operators and managers to track OEE metrics and respond quickly to issues. 

Week 8-10: Review, Refine, and Monitor Progress

After taking action on the steps above, it’s crucial to review progress regularly. This final phase involves fine-tuning your efforts and ensuring sustained improvement. 

Action Steps: 

  1. Review Your OEE Data: Go back to your OEE data and evaluate the improvements made. Identify any areas that still need work. 
  2. Refine Your Processes: Based on data and feedback, refine your maintenance schedules, training programs, and operational processes. 

Conclusion - Why the 10-week plan matters.

Increasing your OEE by 6% to 30% is an ambitious but achievable goal for any plastics manufacturer. By following this 10-week plan, which addresses key areas such as downtime reduction, equipment performance, quality improvement, and operator efficiency, you can begin seeing measurable improvements in your manufacturing processes. 

Remember, the key to success is consistency and a willingness to invest in continuous improvement. As you work through this plan, don’t forget to monitor your progress and refine your approach based on real-time data and feedback. 

With determination and the right strategies in place, your facility can achieve a world-class OEE score and significantly improve its overall efficiency.  

The Intouch Monitoring platform is renowned in helping many of our customers making significant improvements in OEE. With over 25 years of experience in manufacturing, our team is on hand to help you start your journey. Why not get in touch. 

How it works

Getting started with Intouch is as easy as 1, 2, 3

1. Book a demo

Let us show you what we can do. Jump on a demo call and our friendly team will take you through the Intouch system and answer any questions you might have.

2. Enjoy a free trial

Don’t just take our word for it! We’ll lend you our technology for a 60-day free trial so you can see exactly how it can benefit the everyday operation of your business.

3. Receive ongoing support

It doesn’t end there. If you decide Intouch is the right production monitoring system for you, we’ll work with you to help you take control and make significant improvements in OEE.

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