Challenge:
Plant OEE of 61% — driven by high unplanned downtime (18%), slow changeover (avg. 4.2 hours), and quality losses — was limiting production capacity and profitability.
Approach:
Conducted OEE deep-dive analysis, benchmarked against industry standards, implemented TPM Pillars (Autonomous Maintenance, Planned Maintenance, SMED), and predictive maintenance indicators.
Implementation:
Trained 120 operators in autonomous maintenance, reduced changeover from 4.2 to 1.8 hours using SMED, implemented predictive maintenance using vibration analysis.
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