Software and Controls
How to Maximise Your Overall Equipment Eff ectiveness
Josephine Coombe, chief commercial off icer, Nulogy Europe F
or contract manufacturers, maintaining cost-eff ectiveness in production is essential, as even the smallest improvements can lead to signifi cant
fi nancial gains over time. Manufacturing is a business of razor-thin margins and any ineffi ciency can quickly erode profi tability. One of the most eff ective ways to enhance production cost-eff ectiveness is by maximising Overall Equipment Eff ectiveness (OEE), to reduce unnecessary downtime, slow cycle times or quality issues.
WHAT IS OEE?
OEE is determined by three core factors: availability, performance and quality. To ensure operations run at peak effi ciency, these must be optimised.
Availability refers to how much scheduled production time is used for manufacturing. Unplanned downtime, whether due to equipment breakdowns, material shortages or ineffi cient changeovers, can have a signifi cant impact on costs. The more uptime that is lost, the greater the fi nancial strain on operations. Performance measures how eff ectively equipment is running. If machines operate below their optimal speed due to minor stoppages
or labour ineffi ciencies, throughput suff ers. For manufacturers operating in a high-volume, low-margin environment, even small ineffi ciencies can compound into signifi cant fi nancial losses over time. Without real-time visibility, businesses may be unaware of just how much underperformance is impacting their bottom line.
Quality assesses the proportion of units that meet specifi cations. Defective products result in waste, rework and potential reputational damage. Material and labour costs associated with quality failures can quickly add up, particularly when issues are only discovered after large volumes of defective produce have been produced. By optimising OEE, manufacturers can ensure their production lines run as effi ciently as possible, reducing downtime, minimising slow cycle times and improving product quality; all critical factors for maintaining cost-eff ectiveness in a competitive, low-margin industry.
GOING FROM GUESSWORK TO YOUR BEST WORK
By using real-time data insights, manufacturers and contract packers can identify issues as they occur, rather than after they have impacted production. Digital solutions such as Nulogy’s Smart Factory provide real-time monitoring of production lines, giving teams the ability to track availability, performance and quality as production happens. Instead of reacting too late, manufacturers can address ineffi ciencies immediately, preventing unnecessary downtime and safeguarding cost-eff ectiveness. The power of high-quality data allows businesses to take control of their operations. By eliminating manual reporting, manufacturers can optimise labour allocation, ensuring the right number of operators are deployed at the right time. Visibility into materials and inventory prevents delays caused by stock shortages, keeping production fl owing without interruption. With real-time tracking of trends, businesses can continuously improve processes, eliminating recurring ineffi ciencies that reduce OEE. Beyond effi ciency, operational transparency is another key advantage of digitalisation. Real-time collaboration between operators, planners and decision-makers ensures that everyone is working
from the same, accurate information. Instead of relying on assumptions or fragmented data, teams can access a single source of truth, helping them improve productivity and maintain consistent quality across production runs.
CHOOSING THE RIGHT SOLUTION FOR YOUR PRODUCTION ENVIRONMENT For external manufacturers and contract packers, the right digital tools depend on the nature of their production lines. While Smart Factory is built for machine-intensive environments, businesses with
labour-intensive co-packing operations may benefi t from Nulogy’s Shop Floor solution, which provides real-time visibility for manual production workfl ows.
Regardless of the setup, real-time visibility and high-quality data are the foundation for improving OEE. By replacing guesswork with accurate insights, businesses can proactively optimise their operations and maintain peak effi ciency.
FUTURE-PROOFING OVERALL EQUIPMENT EFFECTIVENESS The future of cost-eff ective manufacturing is digital. By embracing real-time visibility and leveraging data-driven insights, manufacturers can optimise OEE and drive productivity gains that lead to signifi cant fi nancial improvements. With Nulogy Smart Factory, manufacturers have the tools to tackle ineffi ciencies head-on and transform their production processes, making cost-eff ectiveness a key driver of success in today’s competitive landscape. Most importantly, improved operational
effi ciency and better downtime management not only boost profi tability but also benefi t customers. By streamlining production, manufacturers can consistently meet deadlines and deliver products on time, in full, which builds customer trust and satisfaction. In the end, enhanced effi ciency leads to stronger outcomes for both manufacturers and their customers, fostering long-term success.
www.nulogy.com
40
April 2025
www.convertermag.com
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