Operations Optimisation

1. Choose the right formula:
• Define your purpose for measuring OEE. Consider whether you want to compare production lines, identify bottlenecks, or improve profit margins.
• Decide the level of monitoring: factory-wide, per production line, per machine, per shift, or per product.
• Explore other metrics like OOE (Overall Operations Effectiveness) or TEEP (Total Effective Equipment Performance) to see if they fit your needs better.
2. Automate data gathering with real-time IIoT:
• Connect your machinery to sensors on the Industrial Internet of Things (IIoT).
• Real-time machine condition monitoring is essential for improving OEE.
3. Apply the 5 Steps of Lean:
• Follow the Lean DMAIC cycle:
• Define: Clearly define your goals.
• Measure: Gather relevant data.
• Analyse: Identify bottlenecks and losses.
• Improve: Implement incremental changes.
• Control: Maintain improvements over time.
• Prioritise factors causing loss and take a step-by-step approach to reduce their impact.

Remember that continuous improvement is key.

1. Assess Your Production Line Equipment:
• Assess the efficiency of your current line equipment. Consider factors like speed, accuracy, and maintenance requirements. 
• Ensure all equipment on the production line is correctly integrated to prevent inefficient use of individual pieces of equipment.
2. Optimise Materials:
• Review your choice and specifications of packaging materials
• Implement strict quality control measures to minimise product waste during filling. Accurate measurements and well-calibrated machinery can significantly reduce material losses.
3. Energy Efficiencies:
• Switch to energy-efficient lighting and heating, ventilation, and air conditioning (HVAC) systems. Timers and sensors can help regulate energy usage.
• Reduce idle time for machinery. Turn off equipment when not in use to save electricity.
4. Preventive Maintenance Measures:
• Schedule routine maintenance for your equipment. Proper lubrication, cleaning, and timely repairs prevent breakdowns and extend equipment lifespan.
• Use predictive analytics to identify potential issues before they escalate. Addressing problems early prevents costly downtime.
• Automate data gathering with real-time Industrial Internet of Things (IIoT). Connect your machinery to sensors
5. Labour Efficiency:
• Train your staff effectively. Well-trained operators can handle machinery efficiently, reducing errors and minimising downtime.
• Optimise shift schedules to match production demand. Avoid overstaffing during low-demand periods.
6. Supply Chain Optimisation:
• Negotiate with suppliers for better pricing on raw materials, packaging, spare parts, and consumables.
• Maintain optimal inventory levels to avoid excess storage costs and prevent shortages.

Regularly monitor your costs, analyse data, and adapt your strategies as needed.

1. Listen to your Employees:
• Show employees that you value their input and ideas. Regularly get feedback through one-on-one conversations, surveys or focus groups. Act on their suggestions to demonstrate that their opinions matter.
2. Invest in and encourage employee development:
• Provide formal development plans.  Encourage cross-training and offer opportunities for challenging assignments. Create career paths. When employees see a path for growth, they are more likely to stay engaged.
3. Recognise and appreciate employees’ efforts:
• Implement employee recognition programmes. Celebrate achievements and contributions. Recognition boosts morale and creates a positive work environment.
4. Encourage a supportive culture:
• Encourage collaboration, teamwork, and mutual respect. Employees who feel connected to their colleagues are more likely to be engaged.
5. Pay and Benefits:
• Ensure that your compensation packages are competitive. 

Employee engagement is an ongoing process. Regularly assess your strategies and create an environment where employees feel motivated and valued.