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Lean OEE

The document outlines eight Lean Manufacturing tools designed to improve Overall Equipment Effectiveness (OEE) for manufacturing processes. Each tool, such as SMED, 5S, and Kanban, is explained with its benefits and real-world examples of successful implementation. The emphasis is on how these tools can reduce downtime, enhance productivity, and ultimately lead to higher profits and efficiency in production.

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13 views

Lean OEE

The document outlines eight Lean Manufacturing tools designed to improve Overall Equipment Effectiveness (OEE) for manufacturing processes. Each tool, such as SMED, 5S, and Kanban, is explained with its benefits and real-world examples of successful implementation. The emphasis is on how these tools can reduce downtime, enhance productivity, and ultimately lead to higher profits and efficiency in production.

Uploaded by

varun
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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EALSS

EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence
EALSS ACADEMY
EALSS Academy
@LEAN6SIGMAPRO

Struggling with low Overall Equipment Effectiveness (OEE)?

If your OEE is below 85%, your machines aren’t performing at their full potential—causing
delays, bottlenecks, and financial losses.

But how do you fix it? Lean Manufacturing provides powerful tools to boost OEE by
improving machine availability, performance, and quality.🚀
Let’s explore 8 game-changing Lean tools that can instantly improve your OEE and
transform your production process! 👇
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

1️⃣ SMED (Single-Minute Exchange of Dies) 🔄


📌 What It Does:
Single Minute Exchange of Dies helps reduce the time taken to
switch between production tasks by eliminating unnecessary
steps and making setup fast and efficient.

📌 How It Helps OEE:


✅ Reduces downtime by cutting setup and changeover times.
✅ Increases available production time without adding shifts.
✅ Helps switch between different product types without
delays.

📌 Example:
A printing company reduced setup time from 45 minutes to just
10 minutes using SMED, increasing its machine utilization by
25%.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

2️⃣ 5S Workplace Organization 🛠️


📌 What It Does:
5s workplace organization improves efficiency by keeping
tools, machines, and workstations organized, ensuring that
operators have what they need when they need it.

📌 How It Helps OEE:


✅ Eliminates wasted time searching for tools or materials.
✅ Reduces minor stoppages and errors caused by clutter.
✅ Improves machine reliability with regular inspections.
📌 Example:
A manufacturing plant applied 5S and reduced equipment
downtime caused by misplaced tools by 40%, leading to faster
machine setup times.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

3️⃣ Kanban System 📦


📌 What It Does:
Kanban is a visual scheduling system that ensures materials
and components arrive just in time for production—preventing
stockouts or overproduction.

📌 How It Helps OEE:


✅ Ensures machines never stop due to missing materials.
✅ Reduces waiting time between process steps.
✅ Prevents overloading workstations, balancing the workflow.
📌 Example:
A car manufacturer used a Kanban system for engine parts,
reducing machine stoppages by 30% due to better material
availability.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

4️⃣ TPM (Total Productive Maintenance) 🔧


📌 What It Does:
Total Productive Maintenance is a preventive maintenance
strategy that involves operators in daily machine care, reducing
the risk of unexpected failures.

📌 How It Helps OEE:


✅ Reduces unplanned downtime by catching issues early.
✅ Increases machine lifespan and reliability.
✅ Improves quality by keeping machines in optimal condition.
📌 Example:
A pharmaceutical company implemented TPM and reduced
unplanned equipment failures by 50%, resulting in higher
machine availability.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

5️⃣ Andon System 🚦


📌 What It Does:
Andon is a real-time visual alert system that notifies operators
and supervisors about process abnormalities, allowing quick
action before issues escalate.

📌 How It Helps OEE:


✅ Reduces the time it takes to identify and fix machine issues.
✅ Prevents minor defects from becoming major problems.
✅ Improves operator awareness and response time.
📌 Example:
A food packaging company installed an Andon light system that
immediately alerted technicians to issues, cutting machine
repair time by 20% and reducing downtime.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

6️⃣ Standardized Work 📋


📌 What It Does:
Standardized Work ensures every operator follows the best,
most efficient way to operate a machine, reducing human errors
and inconsistencies.

📌 How It Helps OEE:


✅ Reduces cycle time variation between operators.
✅ Ensures smooth handovers between shifts.
✅ Improves machine performance by preventing incorrect
usage.

📌 Example:
A metal fabrication plant developed Standardized Work
instructions for machine calibration, reducing process variation
by 60% and increasing consistency in production output.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

7️⃣ Root Cause Analysis (RCA) 🔍


📌 What It Does:
RCA is a problem-solving method that helps identify and eliminate
the root cause of recurring machine failures, instead of applying
temporary fixes.

📌 How It Helps OEE:


✅ Prevents the same machine issue from happening repeatedly.
✅ Improves machine quality and reduces defects.
✅ Helps eliminate waste caused by breakdowns or slow cycle
times.

📌 Example:
A bottling company used RCA to analyze why a machine kept
failing. The root cause was overheating due to a clogged cooling
system. After fixing this, machine downtime dropped by 40%,
improving OEE.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

8️⃣ Heijunka (Level Production) ⚖️


📌 What It Does:
Heijunka ensures work is evenly distributed across
production lines, preventing overload and underutilization
of machines.

📌 How It Helps OEE:


✅ Reduces idle time by maintaining a steady workflow.
✅ Prevents machine overuse, reducing breakdowns.
✅ Improves resource utilization across workstations.
📌 Example:
A home appliance company implemented Heijunka
scheduling, reducing machine waiting time by 15% and
improving throughput.
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

OEE is one of the most important KPIs in manufacturing.

🔹 Low OEE means lost profits, wasted time, and


inefficient processes.
🔹 High OEE means faster production, better quality, and
reduced costs.

Which Lean tool has helped you improve OEE the


most?? Share your thoughts in the comments! 👇
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

📢 Ready to master Lean implementation


with the help of powerful 38 Lean tools and
get certified as Lean Expert?
EALSS
EALSS ACADEMY
Academy
@LEAN6SIGMAPRO
Sustaining Excellence

We would like to invite you to become a


master of Lean Tools by joining our

Lean Expert with 38 Lean Tools Live Training


and 3 Certification Program.
Earn Professional Certification Badges
Need More Information?
Learn more about Lean Practitioner, Lean Leader,
and Lean Expert level training programs...

+91 9665352810
[email protected]
www.ealssacademy.com

@ealssacademy

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