Define

Define:   

 Companion Line OEE Improvement

Objective:
Inconsistent equipment performance (output) is leading to the plant not being able to meet its external demands on the Companion line. Our affiliates have increased our output requirements on the Companion product line by 160,000 units from 07 Oct 13. An additional 1,500 units per shift, based on a 5 day 2 shift cycle between 07 Oct 13 and 20 Dec 13.

Metric	Baseline	Goal	Blue Sky
Line OEE improvement	59%	70%	75%
Unit Output Equivalent	8,496	10,080	10,800

In order to avoid the costly option of Over Time to meet with this demand, the decision was taken to take a look at the line performance from start to finish, this involves the buy-in and commitment of all stakeholders involved - Suppliers, Planning, Manufacturing, Engineering and QA.

A target OEE improvement of 11% (1,500 units)

At €1.11 per set this is an increased financial gain of €1,665 per shift or €16,650 per week, or €183,150 between 07 Oct 13 and 20 Dec 13.

Also the savings achieved over the 11 week period due to the removal of the need to run O.T. at the rate of €8,000 per shiftis a potential saving of €88,000 over the life of this project.

Companion Line CTQ Tree:                        

 













Proposed Project Timelines of DMAIC Phases:

2013

October

November

December

W41

W42

W43

W44

W45

W46

W47

W48

W49

W50

W51

W52

Define

Measure

Analyse

Improve

Control