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Batch size by equipment


Table 2. showing the OEE and component scores for large and small pack lines.


Table 2 above the aggregated overall equipment effectiveness3


Figure 3. showing the batch size by blending equipment. Batch size by product type


and component scores for the large pack and small pack filling lines for the champions and the regional peers. The champion plants outperform the peers on availability, and thus have fewer unplanned stoppages and are better at managing the planned downtime. The utilisation rates of the champions (as indicated by the Performance aspect) for the large packs lines is higher than the peers, although there is a room for improvement for the < 10litre lines. Thus, bigger batches, faster utilisation rates (for large pack lines) and well managed downtime boosts productivity in the packaging department.


Figure 4. showing the batch size by product type.


In the large pack filling department (see Figure 5), champion plants have a 5.6 and 12.5 ton per filling run advantage for Drums and Pails respectively. In contrast, the champions’ small pack batches are smaller in comparison to their regional peers.


Run size by pack type Summary


Figure 5. showing the average run size for large packs (greater than 10 litres). Run size by pack type


The champion plants in EMEA are exploiting economies of scale by producing and filling the finished lubricants in bigger batches in comparison to their regional peers. This, in conjunction with better utilisation rates, low complexity and well managed downtime boost productivity. Ultimately, this streamlined effort enables the champions to have a significant competitive advantage versus regional peers. Champions get to the top by being better managed and more aligned with the rest of the supply chain – not by having more or newer equipment. There is a significant time delay between the installation of new equipment and the reaping of the benefits – which in turn also depends on how well managed the plant is. Champion plants typically invest modestly and focus on few but important goals. This is not the result of magic or coincidence but hard work and professionalism.


LINK www.malikpims.com


Availability takes into account all events that stop planned production long enough where it makes sense to track a reason for being down.


3


Performance takes into account anything that causes the manufacturing process to run at less than the maximum possible speed when it is running.


Figure 6. showing the average run size for small packs (less than 10 litres). Quality takes into account filled packages that do not meet quality standards.


24


LUBE MAGAZINE NO.149 FEBRUARY 2019


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