Regardless of the industry that you’re operating in, manufacturers are always looking for opportunities to cut costs without sacrificing quality. This is especially true as many industries like pharmaceuticals and even food and beverage become increasingly competitive all the time.

Thankfully, there is already an opportunity to do precisely that – it’s just one that far too few business leaders are currently taking advantage of. It’s called Overall Equipment Effectiveness or OEE and it brings with it a host of different opportunities to cut costs that are absolutely worth a closer look.

The Key to Greater Efficiency is Here

To truly get an understanding of how your OEE score impacts your production costs, you must first begin to think about those costs as more than just line items on a balance sheet somewhere. Yes, producing X number of parts costs Y dollars per part – but it’s also a great deal more sophisticated than that.

When you improve your OEE score, you make meaningful gains towards eliminating unplanned downtime and reducing unnecessary stops. You learn the actionable information you need to make the types of changes that will improve line changes and retooling techniques. In other words, you boost availability – something that will allow you to produce more parts without necessarily adding resources like new equipment.

Speaking of that equipment, improving your OEE score also means that you’re improving not only the performance of that which you’re already working with, but the utilization as well. It helps guarantee that all machines are operating at their maximum potential – or at least as close to it as you can get. This, too, helps realize the full potential of your existing infrastructure, thus cutting costs significantly along the way.

Not to mention the fact that if you have a high OEE score, it means that you’re doing your part to avoid poor quality parts that need to be rejected as soon as they come off the assembly line. It means that you’re avoiding going through unnecessary procedures just to arrive at a less-than-desirable conclusion.

When taken together, all of this means a few important things. Your OEE score is a direct indication of how much waste you currently have in your manufacturing process and the more you can eliminate, the easier it becomes to produce A) high quality parts and other components B) as quickly as possible. Once you get to that point, you can start to see the highest possible return on investment of the materials you’re working with, the machines you’re using and even the people you’ve paid to run them – which in and of itself is the most important benefit of all.

If you’d like to find out more information about how improving your OEE score can help significantly reduce your production costs over time, or if you just have any additional questions you’d like to discuss in a bit more detail, please don’t hesitate to contact Thrive today.

Overall Equipment Effectiveness or OEE is one of the most important metrics for manufacturers in the modern era. However, it’s so much more than just a simple number. To truly get as much insight from it as possible, you need to understand what that value actually means. Getting to that point requires you to have an essential context surrounding what you’re measuring and, more importantly, why it matters that you’re paying attention to these qualities to begin with.

What the Data is Really Trying to Tell You

To truly get a sense of what your OEE score is revealing about your operations, you need to come to a greater understanding of how this score is calculated in the first place.

Consider your quality score, for example. Let’s say you produced 20,000 parts in a given period, but had to eliminate 5,000 due to issues with their viability. 20,000 parts minus 5,000 would be 15,000 which, when divided by that original 20,000 production run, would equate to a quality score of roughly 75%.

Now, to be fair – this is not a bad score at all. It’s not necessarily possible to reach an OEE score of 100%, as that would mean that everything was operating at total efficiency – a tall order, to be sure. But it does indicate that there is room for improvement in terms of the quality of your output and once you know that you have the starting point of something far more important.

Unplanned stops could be an issue, for example – those periods where key pieces of equipment fail, when an operator isn’t available to run a machine or when unplanned maintenance takes place. It could even be an issue with planned stops – shift changes are taking too long, machines aren’t being as cleaned as quickly as they should be, etc.

Regardless – once you know that you have an issue, and once you know what it is, you have the actionable information you need to fix it. This, in essence, is what OEE is all about.

All told, OEE is the gold star metric for manufacturing organizations – but looks can be deceiving. Don’t necessarily assume that you can get to a score of 100%, because you can’t. Nobody does. But even if you come out of the gate with a low score, so long as it is always ticking upwards you can be confident that you’re moving in the right direction. Once you hit a score of 85% or above, you can rest easy knowing that you’re doing everything you should be – which is the most important thing of all.

If you’d like to find out more information about how to extract as much value from your OEE score as possible, or if you just have any additional questions that you’d like to see answered in a bit more detail, please don’t delay – contact the team at Thrive today.

At its core, downtime tracking doesn’t just help you better understand the current state of the equipment in your manufacturing facility. It also helps you gain visibility into what that equipment is capable of, and what the potential is when you get as close to peak productivity as possible.

The more information you’re tracking, the more insight you have – and the better choices you can make in terms of optimization.

According to one recent study, it’s estimated that about 70% of all organizations don’t actually know the full extent of their unplanned downtime events. They may know that they have an issue, but they’re not sure why – which means they can’t prevent it from happening again.

Thankfully, downtime tracking solutions like those available from Thrive can help relieve that issue – provided that you pay attention to a few key attributes along the way.

Harnessing Downtime Tracking to Your Advantage

To make sure that you’re deriving the most value from your downtime tracking software, you need to be as detailed in terms of the data that you’re collecting as possible. This means that in addition to capturing the process area or specific line where the downtime event occurred, you also need to make a note of things like the machine itself as well.

Equally important are things like the product that was being worked on at the time of the event. Sometimes, it’s not so much a matter of an issue with the machine as it is an issue with the process itself.

Of course, the length of the event is also paramount to helping better understand what is going on. If you know when an event happened and when it was eventually corrected, you should be able to see this number get shorter over time as you make steps to improve. Operator comments will be equally important to that end, as they can help provide additional insights into an event including what the conditions were and what steps were taken to ultimately fix the problem.

Overall, downtime tracking is about painting a more complete picture than you can arrive at on your own. It’s not just about what happened – it’s about who was involved, when the event occurred and where it took place. All of these help answer the most crucial question of all: “why is this issue happening?” Is it a one-time affair, or is it recurring? What is the context surrounding the issue? Once you’re able to answer those questions, you have nearly everything you need to emphasize continuous improvement across your manufacturing lines – leading to greater efficiency and even greater profits as well.

If you’d like to find out more information about the key attributes that you should be paying attention to in order to get the most out of your downtime tracking efforts, or if you’d like to speak to someone about your own needs in a bit more detail, please feel free to contact Thrive today.

While downtime tracking solutions are undoubtedly powerful, it would be a mistake to consider them a “silver bullet.” Simply investing in such a solution in and of itself is not enough to consistently improve your manufacturing efforts. It’s not an end point – it’s the beginning of something much larger.

This means that to drive real, positive change, you need to be prepared to analyze that downtime tracking data in a variety of different ways, all of which are worth a closer look.

Taking Downtime Tracking to the Next Level

By far, one of the most important steps to take in order to get the most out of your downtime tracking efforts involves conducting a thorough analysis of what your data is trying to tell you.

Case in point: machine failures. Yes, downtime tracking can instantly tell you when a machine goes offline and can likely define a reason why. But how long does it actually take your employees to fix these issues? Is this a number that can be improved as well and, if so, how do you best go about doing it? The answers to these questions cannot only make sure that machine failure events happen less frequently, but that they’re resolved as quickly as possible when they do.

Along the same lines, it’s also important to understand your data within the context of your own manufacturing operations. The volume of data that a solution like Thrive can provide you with is enormous, so you need to pick more specific metrics in order to gain actionable insights about your company. Which metrics matter the most to you? Why is it important to gain real-time visibility into these qualities? These, too, are answers that will vary depending on the organization, which is why it’s so important to answer them as early on in the process as possible.

Finally, consider the end result of downtime tracking – meaning what action you’re actually going to take as a result of your findings. Yes, you want to reduce unplanned downtime events – but you also want to accomplish more than that. Downtime tracking can be a viable way to identify waste in your production efforts, for example, which can and should lead to thoughtful process changes. It may even uncover opportunities for the implementation of new technologies, allowing your employees to work “smarter, not harder.”

Regardless, downtime tracking itself is only the beginning. The true impact rests not just with the data that you’re being provided with, but the actions you take and the decisions you make as a direct result of it.

If you’d like to find out more information about how to dive beneath the data from your downtime tracking solution to uncover the true story of what’s going on with your business, or if you have any additional questions you’d care to talk about in a bit more detail, please don’t delay – contact Thrive today.

Imagine if nearly every device on your shop floor had a sensor built into it. One that was collecting performance and quality data at all times. One that was also sharing data with not only every other machine and sensor, but with organizational leaders as well. The types of insight that you could derive from that information would be enormous – it would generate a type of real-time visibility into your operations that would virtually guarantee continuous improvement on a daily basis.

Thankfully, we’re talking about a category of technology that already exists. It’s called the Industrial Internet of Things (or IIoT for short), and the market is predicted to reach an enormous $124 billion in value by the end of 2021.

Yet despite this, there are still manufacturers out there that insist on doing things “the old-fashioned way” – meaning with manual, time-consuming processes that add little value to the production. All told, embracing the Industrial Internet of Things is not only a good idea, but it’s also one that can dramatically improve your OEE scores as well.

OEE and the IoT: The Perfect Pairing

Short for Overall Equipment Effectiveness, OEE is essentially the most important metric for any manufacturer. Once you begin carefully tracking quality, availability and performance, you gain an incredible level of insight into what you need to do to improve your company moving forward.

The Industrial Internet of Things can help with these efforts in a wide range of different ways. As you collect more and more data from machines and operators, you can go back and look at historical data to optimize virtually all areas of your business. You can see which machines are most likely to go offline, allowing you to spend your budget wisely in terms of what you replace and what you repair. You can see when demand is high and create schedules for employees that avoid bottlenecks. You can make sure important resources are where they need to be, exactly when they need to be there – absolutely no exceptions.

All of this creates something of a perfect storm in the best possible way. Maintenance costs are reduced almost immediately because you can see the “bigger picture” of what is going on. You’re spending less on materials and other resources because you have a better understanding of exactly what you need in a given situation. Equipment is more available and is being better utilized: significantly increasing your return on investment, too.

Quality. Availability. Performance. Those are the three areas of your operations that can be significantly boosted by the Industrial Internet of Things, and they’re the ones that will increase your OEE score as well.

If you’re interested in finding out more about why manufacturers should be embracing the Internet of Things with open arms, or if you have any additional questions that you’d like to go over in a bit more detail, please feel free to contact the team at Thrive today.

One of the most important things to understand about downtime tracking software is that it is not the “be all, end all” solution that many think it is – at least, not on its own.

Yes, it’s valuable to get an automated alert whenever a critical piece of equipment goes offline. But if you don’t know why, meaning you also don’t know what to do about it, what value are you actually getting?

Therefore, if you really want to practice the most effective downtime tracking possible, you’ll want to keep a few key things in mind.

Getting to the Heart of All Those 1s and 0s

By far, one of the most important steps you can take to dive beneath your downtime tracking data involves making sure you understand exactly what it is that you’re tracking in the first place.

A downtime tracking solution like Thrive will allow you to separate events based on a number of different categories so that you see more than just when something is offline – you get visibility into why, all so that you can put yourself in the best possible position to do something about it.

An unplanned downtime event is one when a machine is not working as it should be because of some type of issue you didn’t predict. Obviously, this is different from a scheduled period of downtime which may be some planned event like maintenance or a shift changeover.

It’s also important to acknowledge when a particular machine is not operating because a separate machine upstream in the production line is down. This is similar to when a machine might be blocked – meaning that a downstream machine is offline and something of a bottleneck has developed.

All of these examples are technically downtime instances, yes – but they’re very different situations that require totally different resolutions. If you treat them all as if they’re the same – meaning that if you’re only paying attention to whether or not a machine is online – you’re only getting one small part of a much larger story.

Similarly, you need to make sure that your operators are prepared to assign detailed downtime reasons to all events. This is crucial to the ongoing problem-solving process. Many solutions can help assign downtime reasons automatically, but operator notes are still important to again provide that essential context. Without it, you’ll likely face the same recurring issues again and again – you’ll be treating the symptom, not the disease, so to speak. With accurate downtime reasons, you’ll have total visibility into what is happening and why – all so that you can make meaningful steps to improve your operations in the future.

If you’d like to find out more information about why effective downtime tracking requires you to dive beneath the data to uncover the true story of your business hiding in plain sight, or if you just have any additional questions that you’d like to get answers to, please feel free to contact Thrive today.

Automated downtime tracking solutions like those offered by Thrive collecting meaningful, real-time data from any machine on your shop floor – all so that you can understand exactly what is going on at any given time.

If you know which means are most likely to go offline and why, you have virtually everything you need to prevent recurring issues from happening again in the future. You also have the ability to stop a small problem before it becomes a much bigger and more expensive one, allowing you to get the highest return on investment for your equipment in the process.

Downtime tracking technology has come a long way in the last few years – and now, the Industrial Internet of Things is poised to take it to the next level. Also called the IIoT for short, the Industrial Internet of Things is one of the most important advancements to come along in a generation or more – and it’s one that is certainly worth a closer look. With the integration of Downtime Reduction software, businesses can make the most of the IIoT to not only monitor equipment performance in real-time but also proactively address inefficiencies in their processes. By leveraging this technology, organizations can minimize unplanned downtime, improve productivity, and gain a substantial competitive advantage in their respective industries.

The IIoT Has Arrived

At its core, the IIoT refers to a vast network of sensors and similar “smart” devices that are all connected not only to your equipment, but to each other. They’re constantly monitoring assets, collecting data, sharing and analyzing it – all so that you have the most complete picture to work from at all times.

In the world of manufacturing, the biggest advantage of this approach comes by way of preventative maintenance – something that should always be the cornerstone of any downtime tracking process. For years, businesses have been forced to contend with a “break/fix” model when it comes to maintenance – meaning that outside of regularly scheduled service periods, you essentially had to wait for something to break so that you could properly fix it. With advancements in technology, however, organizations can now prioritize Downtime Reduction Through Process Optimization, leveraging actionable data to streamline operations and ensure equipment reliability. This forward-thinking approach not only minimizes disruptions but also provides enhanced insights for predictive maintenance strategies, moving beyond the limitations of reactive solutions.

With the IIoT and preventative maintenance, however, you can be much more proactive about the entire situation. Sensors can automatically alert you whenever conditions deviate outside the accepted definition of “normal.” That way, you can address smaller issues before they turn into periods of unplanned downtime at all.

Not only that, but when combined with data collected from your downtime tracking solution, you can also see the exact perfect moment to take a machine offline for maintenance so that it causes the least amount of disruption to the rest of your production.

In the end, the Industrial Internet of Things is just getting started – it will be composed of literally billions of devices over the next few years. All of this is excellent news for manufacturers who embrace it as it will help them continue to improve their operations moving forward.

If you’re eager to learn more information about where concepts like the Industrial Internet of Things may be taking the world of manufacturing and how they’re empowering things like downtime tracking, or if you’re just looking to discuss your own situation in a bit more detail, please feel free to contact Thrive today.

Measured on a scale of 0% to 100%, Overall Equipment Effectiveness or OEE is arguably the single most important metric you could be tracking. But those who are new to this world are often discouraged by how slow progress may seem – at least initially. But the arc of change may be slow, but it’s also incredibly consistent – meaning that small but pivotal advancements are a lot more essential than most think.

Slow and Steady Wins the Race, or: Why Incremental Improvements Are Key

For the sake of example, let’s say you spend weeks or even months collecting enough actionable data to come up with your first OEE score. You run the numbers, you double check everything and you get a score of 80%.

Obviously, this shows that you still have a bit more room for improvement – as is true with just about any manufacturing enterprise you can think of. You dive beneath the data, you identify opportunities to eliminate waste and you make some fundamental changes to not only your equipment, but also your line operators and more.

Then, after a period of time, you run the numbers again. You calculate your OEE score… and it’s only increased by one or two percentage points.

Clearly, you’ve gone to a significant amount of effort up to this point. You feel like you’ve done everything right and your gains should have been larger. Still, provided that you’re confident in the quality of the data you’re working with, those numbers don’t lie.

Make no mistake about it: this is not the bad thing you think it is.

For starters, you still have a lot of intelligence to work from to continue to make adjustments moving forward. Remember that the operative word in the phrase “continuous improvement” is “continuous” – meaning that if you’re confident that you’re moving in the right direction, there’s nothing to be upset about.

But think for a moment about what would happen if you continued to home in on those areas of waste and other inefficiencies that might be costing you money. Let’s say you’re able to increase that OEE score another one or two percentage points every few months for the next year. Think about where you’ll be 12 months from now and how much progress you’ll have made.

In the end, it’s important to remember that OEE isn’t just about where you are – it’s also a way to measure where your organization is headed. Provided that you’re drawing the right conclusions from your data and are taking meaningful steps to act on that information, it doesn’t matter how long it takes. Eventually, you’ll be exactly where you need to be – and that in and of itself is the most important benefit of all.

If you’d like to find out more information about why incremental improvements to your OEE score matter far more than a lot of people realize, or if you just have any additional questions that you’d like to discuss with someone in a bit more detail, please feel free to contact the team at Thrive today.