Factors that reduce production efficiency

OEE - Overall Equipment Efficiency is an important indicator of production performance in each factory.

In the structure of investment in almost manufacturing factories, equipment usually are most expensive component, directly determining the cost of each product. A good OEE indicates is show a good business performance, from ensuring enough orders for production, optimal operating efficiency and quality standards. So, what are the factors that cause a decrease in efficiency, a decrease in OEE?

OEE is made up of 3 values: Availability, Performance and Quality. Each value group is affected by many factors that can cause damage and waste to reduce the index. As detail below:

• Availability: This index is reduced when downtime is increased. There are 2 activities causing the biggest impact includes :
  • Damaged machinery and equipment: Machine’s components stop, error or wrong mold, mechanical or electrical failures, unplanned maintenance
  • Setup and adjustment: Standard and process are not optimal will cause these losses. For example: setting parameters on startup, setting or changing molds, changing models, specifications, etc.
• Performance: planned performance will not be achieved if there are following factors :
  • Abnormal stop: also known as a “small stopped”, it is not a malfunction of equipment and devices. The incidents can cause pauses such as: wrong or missing materials, sensors obscured by the wrong movement of workers, the flow of products on the conveyor is congested, stuck, distance between products are not wide enough causes counting errors …
  • Low-speed operation: Operation at low speeds compared to the plan may occur situations: improperly serviced machinery and equipment that cause poor performance, environmental / weather, wrong parameter settings, workers are not same capacity and skill
• Quality: Product quality ensures production efficiency, the commitment and reputation of the business. Quality is affected by the following main activities:
  • Wrong installation and start up: in addition to causing a reduce of up-time of machinery and equipment, it also causes a product error that affects the quality. If these defect products are not detected early and go to later stages, they will cause even more consequences.
  • Error in manufacturing: when all operation parameters are normal can still produce defective products. The earlier the detection will reduce error products, improve quality rate.

How to minimize the losses above? The answer is IIoT – a solution for intelligent connectivity and monitoring in industry. Solution of connecting machines and equipment by sensor system, synchronous communication about central software, helping factories:

• Collects all information of production activities continuously in real time
• Monitor the performance indicators, promptly detect abnormal factors causing losses
• Analyze operating history data, performance and quality data to detect bottlenecks, have plans to optimize production plans, maintenance plans and resources use.
• Ensure accurate predictions to provide materials in the right place, the right place, the right amount (Just-in-time)

The iAndon solution will bring sustainable value so the factories can monitoring, analysis and improve OEE in a continuous, synchronized and effective way.