Last updated on Aug 2, 2024

How can you improve your machines' effectiveness?

Machines are essential for manufacturing, but they can also be a source of inefficiency, waste, and downtime. If you want to improve your machines' effectiveness, you need to optimize their performance, maintenance, and integration. In this article, you will learn some practical tips on how to do that.

1 Monitor your machines

The first step to improve your machines' effectiveness is to monitor their condition, output, and usage. You can use sensors, data loggers, and software tools to collect and analyze information about your machines' health, productivity, and energy consumption. This will help you identify any issues, anomalies, or opportunities for improvement. You can also use dashboards, reports, and alerts to visualize and communicate your machine performance data to your team and stakeholders.

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Francisco Velasco G

Strategy & Operations Manager @LCG | MBA @EGADE | BSc. Mechatronics Engineering @TecdeMonterrey | SCRUM Master
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The optimal practice is to collect data from PLC so you can focus maintenance, and any improvement needed in the machine. Sometimes is not possible to get PLC data in all machines or all stations, then it´s my recommendation to manually monitoring the operation and reach the maximum Performance posible during the production. Using that Performance best result, I have implemented usage of low-code apps where operators and supervisors register the start time and stop time of any event, and then calculate if my pain point was Performance or Availability. I recommend PowerApps or AppSheet for a record app with basic columns: Machine/Operator, PO, Product, Date, Time, Event (drop-down list), Attach (photo), Comments, plus any other needed.

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2 Maintain your machines

The second step to improve your machines' effectiveness is to maintain them regularly and proactively. You can use preventive, predictive, and condition-based maintenance strategies to prevent breakdowns, reduce repairs, and extend your machines' lifespan. You can also use spare parts inventory management, maintenance scheduling, and work order management systems to optimize your maintenance resources and activities. By maintaining your machines, you can improve their reliability, availability, and quality.

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Francisco Velasco G

Strategy & Operations Manager @LCG | MBA @EGADE | BSc. Mechatronics Engineering @TecdeMonterrey | SCRUM Master
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If the machines are not in good conditions, you cannot expect good OEE from daily operation. What you can expect is preventive maintenance to be done every day or every time the machine starts operation. This aiming to prevent the most-critical failure and the most common ones. I implemented this routine in my most-recent project (steel manufacturing) increasing up-time from 35% to 60% during good days (several unrepeated failures took place) but it was not enough. A complementary solution was to schedule total shutdowns of each machine to execute an overhaul. That 2 to 4 days stop per machine, increased availability to +80%

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3 Integrate your machines

The third step to improve your machines' effectiveness is to integrate them with your other systems and processes. You can use automation, connectivity, and interoperability technologies to enable your machines to communicate and coordinate with each other, as well as with your human operators, suppliers, and customers. You can also use lean, agile, and flexible manufacturing methods to adapt your machines to changing customer demands, market conditions, and production goals. By integrating your machines, you can improve their efficiency, flexibility, and responsiveness.

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4 Train your operators

The fourth step to improve your machines' effectiveness is to train your operators on how to use, control, and troubleshoot them. You can use manuals, videos, simulations, and on-the-job coaching to teach your operators the skills and knowledge they need to operate your machines safely, correctly, and efficiently. You can also use feedback, incentives, and recognition to motivate your operators to follow best practices, improve their performance, and report any problems. By training your operators, you can improve their competence, confidence, and satisfaction.

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5 Upgrade your machines

The fifth step to improve your machines' effectiveness is to upgrade them with new features, functions, and technologies. You can use innovation, research, and development to identify and implement new ways to enhance your machines' capabilities, performance, and value. You can also use benchmarking, testing, and evaluation to measure and compare your machines' effectiveness before and after the upgrades. By upgrading your machines, you can improve their competitiveness, differentiation, and profitability.

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6 Review your machines

The sixth step to improve your machines' effectiveness is to review them periodically and systematically. You can use audits, inspections, and assessments to check your machines' compliance, safety, and quality standards. You can also use surveys, interviews, and feedback to collect your operators', customers', and stakeholders' opinions and suggestions on your machines. By reviewing your machines, you can improve their alignment, improvement, and accountability.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Francisco Velasco G

Strategy & Operations Manager @LCG | MBA @EGADE | BSc. Mechatronics Engineering @TecdeMonterrey | SCRUM Master
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We all operations manager should care about our operation teams and their fulfillment in the job. What I found out in the steel manufacturing plant was that most operators didn't care about the job or production results as they were not planning to stay around more than a year. And this caused troubleshooting to take either 15 min or 4 hours depending on operators' engagement. Together with the Talent Department of the company, we deployed three main tactics to increase engagement of the operators: highlighting benefits the job, updating variable compensation based on OEE, and training session during the whole year. This worked to increase engagement from the operations staff.

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How can you improve your machines' effectiveness?

1

2

3

4

5

6

7

1 Monitor your machines

2 Maintain your machines

3 Integrate your machines

4 Train your operators

5 Upgrade your machines

6 Review your machines

7 Here’s what else to consider

Manufacturing

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How can you improve your machines' effectiveness?

1

2

3

4

5

6

7

1 Monitor your machines

2 Maintain your machines

3 Integrate your machines

4 Train your operators

5 Upgrade your machines

6 Review your machines

7 Here’s what else to consider

Manufacturing

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