10 Case Studies Exploring Overall Equipment Effectiveness (OEE)
In this article, we’ve compiled a collection of 10 case studies on Overall Equipment Effectiveness (OEE). Discover how organizations are leveraging OEE metrics to optimize manufacturing performance, reduce downtime, and boost operational efficiency.
OEE is a comprehensive measure of how effectively manufacturing equipment is utilized, taking into account 3 key components: availability, performance, and quality. It provides a clear framework for identifying and addressing inefficiencies, allowing organizations to maximize the productivity of their assets. These case studies explore a variety of strategies and tools used to improve OEE, from implementing predictive maintenance and advanced analytics to streamlining workflows and enhancing operator training.
Learn how organizations are tackling challenges such as unplanned downtime, underperformance, and production defects while driving continuous improvement and maintaining a competitive advantage in today’s fast-paced manufacturing environment.
For each of these case studies, we’ve provided the background and a link for more information. Each case study includes an in-depth competitive strategic analysis, presenting the evaluations, implementation plans, and results.
1. Total Productive Maintenance for Mid-Size Warehousing and Storage Company in E-commerce
Background: A mid-size warehousing and storage company specializing in e-commerce fulfillment is challenged with 20% downtime, affecting overall equipment effectiveness. The organization faces internal challenges such as outdated warehousing equipment and inefficiencies in maintenance practices, leading to a 15% increase in operational costs. External pressures include rising customer expectations for faster delivery times and increasing competition. The primary strategic objective is to enhance operational efficiency and reduce downtime by implementing Total Productive Maintenance to improve overall equipment effectiveness.
Read the full case study here.
2. Operational Efficiency Boost for Engineering Firm via Total Productive Maintenance
Background: An engineering firm specializing in precision components is facing a 20% decline in overall equipment effectiveness due to operational inefficiencies. Internally, the company grapples with outdated maintenance practices and a lack of skilled technicians, leading to equipment downtime and reduced productivity. Externally, the organization faces increasing competition from firms adopting advanced manufacturing technologies. The primary strategic objective is to enhance operational efficiency through the implementation of Total Productive Maintenance (TPM) to regain market competitiveness.
Read the full case study here.
3. Renewable Energy Plant Efficiency Enhancement
Background: The organization operates within the renewable energy sector, focusing on solar power generation. It has recently grappled with suboptimal Overall Equipment Effectiveness (OEE) across its network of plants. Despite substantial investments in state-of-the-art solar technology, the organization’s energy output has not met projected capacity, with significant unplanned downtime and maintenance issues. The challenge lies in enhancing the efficiency and reliability of equipment to boost productivity and reduce energy generation costs.
Read the full case study here.
4. Enhancing Overall Equipment Effectiveness for High-tech Manufacturing Firm
Background: An multinational electronics manufacturing firm with sizable production lines spread across various continents is dealing with declining Overall Equipment Effectiveness (OEE). Despite several technological advancements and investment in high-tech equipment, the firm has evidently observed below-par productivity, higher maintenance costs, and longer unplanned downtimes. This situation has led to lower profit margins and market competitiveness.
Read the full case study here.
5. Equipment Effectiveness Enhancement in Packaging
Background: The organization is a mid-sized entity specializing in packaging solutions for the food and beverage industry. It has recently expanded its operations, leading to a significant uptick in demand. However, the company is encountering challenges in maintaining optimal Overall Equipment Effectiveness (OEE), with noticeable dips in production efficiency and quality output. This has resulted in increased cycle times and waste levels, directly impacting the organization’s cost structure and market competitiveness.
Read the full case study here.
Background: A mid-size construction firm specializing in commercial building projects is grappling with a 20% decline in overall equipment effectiveness due to inadequate TPM practices. The organization is facing internal challenges such as frequent equipment downtime and suboptimal maintenance schedules, alongside external pressures including rising material costs and increasing competition. The primary strategic objective is to enhance operational efficiency and profitability through improved maintenance practices and equipment utilization.
Read the full case study here.
7. Overall Equipment Effectiveness Boost in Aerospace Manufacturing
Background: An aerospace components manufacturer in North America is grappling with suboptimal Overall Equipment Effectiveness (OEE) scores, impacting its competitive edge in a high-stakes market. With a recent uptick in demand for aerospace parts, the manufacturer is struggling to meet production targets due to frequent equipment breakdowns, unscheduled maintenance, and production bottlenecks. Inefficiencies have led to increased cycle times and cost overruns, eroding the organization’s profitability and threatening its long-term contracts with key industry players.
Read the full case study here.
8. Overall Equipment Effectiveness Boost in Power Sector
Background: A power generation firm in North America is facing challenges with its Overall Equipment Effectiveness (OEE). Despite significant investments in advanced machinery and technology, the organization’s equipment is not performing at the expected levels of productivity and reliability. Unplanned downtime, slow rates of production, and quality issues are impacting the organization’s ability to meet demand and operate efficiently. The organization seeks to optimize OEE to reduce costs and improve service delivery.
Read the full case study here.
9. OEE Improvement for D2C Cosmetics Brand in Competitive Market
Background: A direct-to-consumer (D2C) cosmetics company is grappling with suboptimal production line performance, causing significant product delays and affecting customer satisfaction. Despite a robust market presence and a loyal customer base, the organization’s Overall Equipment Effectiveness (OEE) scores are below industry benchmarks. The organization aims to identify inefficiencies within its manufacturing process, optimize equipment performance, and reduce downtime to better meet demand in a highly competitive vertical.
Read the full case study here.
10. Infrastructure Asset Management for Water Treatment Facilities
Background: A water treatment firm in North America is grappling with suboptimal Overall Equipment Effectiveness (OEE) scores across its asset portfolio. Despite heavy capital investment in infrastructure, the company faces downtime and maintenance challenges that undermine operational efficiency and profitability. With regulatory compliance costs rising and water quality standards tightening, the organization needs to optimize OEE to ensure sustainable service delivery and maintain its market position.
