System improvements are brought about by the new Design for OEE methodology.

 If your firm uses automation to increase productivity, as most businesses do, OEE is a crucial statistic for evaluating where improvement efforts should be directed. All three OEE components—Availability, Performance, and Quality—apply if most of your production stages involve manufacturing machinery.

 

The component results have averaged 90%, 86%, and 98.7%, respectively, for the firms I have tracked and following some improvement attempts. The OEE for this is 76.4%. OEE of 85% is typically used as a world-class benchmark by enterprises. Even this standard for excellence can be surpassed with a change in emphasis regarding where improvements are made.

 

Most Lean Six Sigma practitioners have seen the cost and quality advantages of DFSS in the New Product Introduction process. Design For Overall Equipment Effectiveness, or DFOEE, is something I would want to propose that is similar and equally as advantageous. I agree that the DFSS technique may be used for machine design, and some of its approaches are contained within DFOEE before all DFSS purists start getting agitated. The primary distinction is between focusing on the OEE components and the entire production system. So let's talk about the DFOEE process now.

 

The primary Lean tools and techniques, particularly waste elimination, are used during the machine design. This process also begins with forming a varied team, with participation from all departments, including the Supplier (and its essential component suppliers), the value-add personnel who will operate the machine, Sales, and Customers. The value-adding processes that the machine executes are the main emphasis of the design process, and all of the non-value-adding steps in the initial blueprint are minimized. Significantly less material must move through the machine, increasing throughput while enhancing quality by reducing errors like jams, scratches, and dirt. Another outcome of these advancements is typically a reduction in footprint.

 

Simplifying, combining, reducing adjustment through feedback loops, and even turning internal chores into exterior duties like automatically switching tools and making mechanical adjustments are some of the SMED concepts.

 

By removing pointless sensors and unused software and providing a wide range of product configurations, the DFSS concepts are immediately used to reduce variation.

 

Preventative maintenance can be made simpler by segmenting the machine, employing predictive maintenance on these segments, and then using a modular replacement for the higher-wear components. One tool should be able to perform all maintenance because most fasteners are rapid-release.