OEE up 22% across the factory
We were engaged by the Manufacturing Director of a £200m business to lead / guide the operational team to stabilise a shop-floor of 600+ machines working 3 shifts (plus overtime) producing very poor OEE performance.
We diagnosed weaknesses in 3 areas
No structured 5s / TPM mechanism
Ops leaders didn’t understand basic control requirements
No method existed to sustain and continue improvement.
In response we
Helped the team to develop a strategy for breaking down the shop and prioritising areas / machines
Identified skills weaknesses at Manager / Cell Leader / Team Leader level and trained them hands on 5s & TPM
Created and trained 6 zone champions
Created visual control kamishibai style 5s / TPM approach to manage and drive improvement (6) Introduced layered audit and confirmation process for 5s / TPM auditing with a kaizen mechanism.
As a result OEE improved by an average of 22% across 25 key machines and the system has been sustained for some years now across the entire range of machines and processes. Knowledge was transferred to the zone champions and local Cell & Team Leaders.