Background
The client is a leading manufacturer of transmission line towers with operations across substations, infrastructure and industrial electrification projects, offering integrated solutions for a broad spectrum of power transmission and distribution undertakings.
The client had factories in three different cities and wanted to gain visibility of the operations to analyze productivity trends, handle breakdowns and perform condition monitoring of 50+ key machines remotely from their headquarters.
Challenge
Given the above context, the factory heads of the client’s plants were typically faced with these challenges that needed to be addressed:
1. Accurately determining OEE
Overall Equipment Effectiveness (OEE) is a product of machine availability, performance, and quality of output. Hence, OEE is an all-encompassing measure of how effectively assets are being used in producing quality output.
- Firstly, considering the components of OEE, the machine availability concerns how downtime can be minimized, especially that which is unplanned.
- Secondly, the performance of the machine is a measure of how effectively it is utilized in the available time to produce the desired output. Performance concerns include line balancing - essentially balancing the operator and machine times to ensure least idle periods.
- Finally, the third component of the OEE deals with the quality of the output produced. This is a ratio of the actual number of components that meet all requirements over the total numbers produced.
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