Task: Optimise OEE Performance in Engine Valve manufacturing link line
Approach: Direction of Multifunctional problem solving team to target main areas of weakness
Key Steps:
-
Form and train the multifunctional team
-
Simple Industrial Engineering techniques
-
Process Cycle Timings
-
Activity Sampling
-
OEE and its constituents
-
Simple problem solving methodologies
-
Walk the line process-by-process recording observations and concerns
-
Actual cycle time Vs standard
-
Stoppages and causes
-
Operator observations and improvement ideas
-
Review as a team to agree areas of primary concern
-
Cycle time of the bottleneck resource Vs ‘standard’
-
Rework loops
-
Short and longer term stoppages
-
Determine and set a clear standard for the bottleneck resource based on the optimal balance between speed and tool
wear
-
Implement the new standard and control via a Standard Work Instruction for shift handovers
-
Implement fixes for rework loops
-
Production study to better understand the myriad short term stoppages
-
Implement longer term maintenance fixes and ongoing maintenance ‘checks and adjustments’ to resolve stoppages issues
-
Introduce Autonomous Maintenance to manage ‘checks and adjustments’ demand.
-
Continue to manage the improvement process proactively Vs ambitious OEE targets.
Benefits: From 53% OEE to consistently >70% OEE - >32% improvement