David Brown’s Post

Check out our latest blog which outlines how manufacturers can enhance their efficiency through data-driven decisions at machine, plant and enterprise level. Read more: https://lnkd.in/eB5cy4rV

Making the Most of Your Equipment: Why Measuring OEE Matters If you’re in the manufacturing industry, you’ve probably heard of Overall Equipment Effectiveness (OEE). But it’s not just another metric to track, rather it’s a real world indicator of how well your equipment is being used. OEE helps you understand three things. FIrst, is the equipment available when it should be? Is your equipment performing at its best? Lastly, are the parts you’re making meeting your specification? Knowing these is critical to understanding and subsequently addressing OEE gaps and improving the output of your manufacturing floor. The impact of understanding OEE goes beyond operations though. It serves as a framework for justifying new investments or changes to a process. Solid data is key to backing up decisions and it allows you to make a stronger case for what, where, and when to spend. Let’s take something that can be relatively complicated, and simplify: Better use of equipment means lower costs and higher profitability. If you’re not tracking OEE yet, it’s worth starting. #manufacturing #OEE #efficiency #financialdecisions #processimprovement #excellence

Most managers want to improve OEE on all manufacturing lines, but why? OEE is not an end goal, it doesn’t bring you any money, at least not directly. It’s just a measuring tool for efficiency losses. Yet every manager seems obsessed by it. So let’s dive into how you can put a value to OEE improvements. How to determine what to do with the created machine time. When OEE improvement projects are really worth it. #continuousimprovement #oee #manufacturing https://lnkd.in/eHz3SWW2 For a full understanding on how to calculate improvement savings, heck out my course on that very topic: https://lnkd.in/gDysUa8y

"16 Losses" The term "16 losses" typically refers to a detailed categorization of inefficiencies in production or operational environments, particularly in manufacturing, based on methodologies like Total Productive Maintenance (TPM) or Lean Manufacturing. These losses are divided into categories, typically addressing equipment, human resources, and processes. Here's an overview: ### Equipment-Related Losses 1. **Breakdown Losses**: Time lost due to machine breakdowns. 2. **Setup and Adjustment Losses**: Time lost during setup and changeover of machines. 3. **Idling and Minor Stoppages**: Losses due to small, short interruptions. 4. **Speed Losses**: Losses caused by running machines at speeds lower than their designed capacity. 5. **Startup Losses**: Inefficiencies during machine startup or after a stoppage. 6. **Defect and Rework Losses**: Time lost due to defects and the need for rework. ### Human-Related Losses 7. **Operational Motion Losses**: Inefficiencies caused by excessive or unproductive motions by workers. 8. **Line Organization Losses**: Losses due to poorly organized workspaces or workflows. 9. **Management Losses**: Inefficiencies caused by lack of proper supervision or poor planning. 10. **Manpower Losses**: Loss of productivity due to absenteeism, lack of skill, or poor utilization of workers. ### Process-Related Losses 11. **Waiting Time Losses**: Time lost due to waiting for materials, information, or equipment. 12. **Logistics Losses**: Inefficiencies in material handling, transportation, or storage. 13. **Process Defect Losses**: Losses due to defects or scrap generated during the process. 14. **Energy Losses**: Excessive energy consumption or energy waste in processes. 15. **Tooling Losses**: Losses related to tool wear, incorrect tools, or inefficient tool management. 16. **Yield Losses**: Losses caused by deviation from standard production quantities or yields. These losses are often identified and addressed to improve operational efficiency and reduce waste in production environments.

📊 *Keeping OEE Simple* OEE data needs to be understandable and actionable to create leaner processes and to foster an inclusive culture of continuous improvement. Overly complicated systems can intimidate rather than empower - particularly affecting those on the production floor who interact with machinery and processes directly. It's time to consider a simpler, more inclusive approach to OEE if you're looking to streamline your operations and make OEE a central pillar of your continuous improvement efforts. Find out how: https://lnkd.in/eXJbqpU5 #OEE #continuousimprovement #leanmanufacturing

Need assistance managing fleet maintenance or integrating truck data into your maintenance schedule? Let us streamline your process at leantech.com #fleetmaintenance #data #operations #manufacturing #management

From excess to efficiency: Delve into the transformative power of automation in ensuring optimal inventory management and minimal waste.

Excellent visual representation of the benefits of One-Piece Flow vs Batch Production. It can be applied to almost every industry and business. Do you apply One-Piece Flow in your business? Let me know in the comments. #leanthinking #leanrecruiting #efficiency

Processes are often plagued by inefficiency Batch Production is a traditional manufacturing method where identical or similar items are produced in batches, before moving on to the next step. Some manufacturers argue large batches balance workloads and minimize changeovers. But data often shows otherwise. Overlong production runs cause overproduction. Operators lose focus working on large batches, while equipment drifts out of standards between changeovers. Main drawbacks: -Piles of WIP inventory waiting for the next step -Defects hide among the batches -Inefficient space management -Uneven workflow -Long lead times Those lead to: -Some stations being overloaded, others waiting -Low responsiveness to customer demand -More scrap and rework -Higher carrying costs -Facility costs up Switching to One-Piece Flow can bring relief. Workstations are arranged so that products can flow one at a time through each process step. Changeovers become quick and routine. Main advantages: +High customer responsiveness +Minimal work-in-process inventory +Quality issues are detected immediately +Reduced wasted space and material handling +Easy to level load production to match takt time The selection between batch processing and one-piece flow can have significant impacts on quality, productivity, and lead time in a manufacturing process.