How to Reduce Quality Losses: A Straightforward Guide

Although the trends and patterns that OEE (overall equipment effectiveness) helps you discover may be complicated, the concept at the heart of it is anything but. You’re simply talking about the rate at which you’re manufacturing A) high-quality parts, B) as quickly as possible, C) with as little stop time as you can manage.

An OEE score of 100% would mean that you were manufacturing ONLY those quality parts, as quickly as you can, with total availability across the board. Obviously, no business is ever going to get to that point – but it’s still important that you continue to try.

Naturally, a big part of that issue involves quality losses. Defective products make up a big percentage of lost revenue for any organization, so naturally you want to put a stop to it wherever you can. Getting to that point isn’t necessarily difficult, but it does require you to keep a few key things in mind.

Reducing Quality Losses the Actionable Way

One of the best ways to reduce quality losses – and thus improve your OEE score – involves lowering startup rejects wherever possible.

Startup rejects are actually a great place to begin to that end, because they’re fairly easy to track. They tend to rear their ugly heads during that gap between project startup and steady production, where you have a better idea of what you’re dealing with. These tend to be a result of not only errors in the setup process, but also changeovers, equipment readiness issues and more.

One way to reduce these types of startup rejects involves actually ramping back your initial production. The first batch of products to go across your production lines will naturally have some issues. But instead of throwing out a large volume of products and restarting, instead produce a much smaller amount to spot any potential problems early before they have a chance to become much bigger (and more expensive) ones later on.

You could also try reducing variation – which is a term used to describe situations where you may have perfectly fine quality products one day, only to experience significant issues the next. Variation is caused by an unfortunately large list of issues, including inconsistent settings from one machine to the next and inconsistencies in terms of material quality.

To avoid this, figure out why you’re experiencing issues in variation and do whatever you can to solve them. Typically, this involves getting even more strict in terms of those factors outlined above. Not only does this allow you to achieve much more consistent results across the board, but it also goes a long way towards saving your organization as much money as possible.

If you’d like to find out more information about the actionable steps that you can take to reduce quality losses, or if you’d just like to experiment more with how downtime tracking can benefit your organization, please don’t delay – contact the team at Thrive today.