Control

Control:

 Companion Line OEE Improvement


As mentioned in the improve phase, a periodic maintenance schedule was put in place on both the Assembly machine paper banding station and the Flowrapper crimping station, this in theory is a form of preventative maintenance carried out to prevent an accumulation of unscheduled short stops on the Line.

Sample Line Side Paper Band Cleaning Verification Sheet:

 In order to simplify the line layout and ensure the commodities were to hand for operators at all times, we looked at the drop off locations used on the line by service personnel to replenish commodities, we identified some areas that were not clearly visible and identifiable by machine operators and service personnel alike, an example of an improvement can be seen below:

As part of the over DMAIC Improvement project the following improvement in OEE was realised:

At the start of the project a total of 160,000 units was the targeteted improvement in the line performace in for the 57 Production days between the 07-Oct-13 and 20-Dec-13.
Based on the realised project OEE improvement of 4.5%, this means the project realised a total unit gain during a 2 cycle 8 hour shift pattern for the period 73,530 units.

 Although the project did not meet it required improvement goal of 70% OEE or an increase in shift out put of 1500 units, we did achieve an overall OEE improvement of 4.5% or an additional 73,530 units over the life time of the project.

As can be seen below, this increase in output removed the need to run 8 Saturday overtime shifts at a cost of ~ €8,000 each, an overall project saving realised of €64,000.