C.J. Bamber, P. Castka, J.M. Sharp and Y. Motara
Overall equipment effectiveness (OEE) is being used increasingly in industry. This paper defines OEE and explores the purpose of this concept in modern operations. The paper…
Abstract
Overall equipment effectiveness (OEE) is being used increasingly in industry. This paper defines OEE and explores the purpose of this concept in modern operations. The paper discusses OEE as a total measure of performance that relates the availability of the process to the productivity and quality of the product. Therefore, the concept of OEE is appropriate to all operations containing plant and machinery. Research has shown that the most successful method of employing OEE is to use cross‐functional teams aimed at improving the competitiveness of business.
Details
Keywords
The purpose of this paper is to address the gap between definition and practical aspects of production efficiency in mass customization (MC). The paper summarizes all major issues…
Abstract
Purpose
The purpose of this paper is to address the gap between definition and practical aspects of production efficiency in mass customization (MC). The paper summarizes all major issues impacting efficiency in MC. Also, the paper reviews metrics, relationship between various parameters and provides a best practices benchmark toolkit to achieve higher machine efficiencies.
Design/methodology/approach
The paper identified and categorized multiple challenges impacting machine efficiency in MC through a literature review spanning over three decades, and also ranked the identified issue-based parameters. Top issues were found varying across different types of industries identified through the review. Metrics pertaining to efficiency and degree of MC are reviewed in the paper. A chronological review of issues is presented, and a chain diagram is built in the paper. Toolkit of best practices created with solution strategies and tools are summarized through the review.
Findings
The paper found that MC reasonably impacts machine efficiency which needs to be addressed. Major issues through literature review-based ranking are uncovered, and worldwide research trend and comparison are presented. Active research in this area is observed to be at its peak since 2010. The extensive use of strategies and benchmark toolkit for improving efficiency are summarized.
Research limitations/implications
Ranking of issues has been done through a literature review; hence, there can be skewness depending on the frequency of issues researched by various authors in various areas of industries.
Practical implications
This paper is useful for manufacturing managers and companies willing to increase the size of their product portfolio and choices within their available resources without compromising machine efficiencies and, thereby, the cost. The identified issues help in providing a comprehensive issue list to the academia.
Originality/value
This paper describes what is believed to be the first study that explicitly examines the issues faced in achieving machine efficiency while manufacturing in an MC environment.
Details
Keywords
The purpose of this paper is to review the literature on maintenance management and suggest possible gaps from the point of view of researchers and practitioners.
Abstract
Purpose
The purpose of this paper is to review the literature on maintenance management and suggest possible gaps from the point of view of researchers and practitioners.
Design/methodology/approach
The paper systematically categorizes the published literature and then analyzes and reviews it methodically.
Findings
The paper finds that important issues in maintenance management range from various optimization models, maintenance techniques, scheduling, and information systems etc. Within each category, gaps have been identified. A new shift in maintenance paradigm is also highlighted.
Practical implications
Literature on classification of maintenance management has so far been very limited. This paper reviews a large number of papers in this field and suggests a classification in to various areas and sub areas. Subsequently, various emerging trends in the field of maintenance management are identified to help researchers specifying gaps in the literature and direct research efforts suitably.
Originality/value
The paper contains a comprehensive listing of publications on the field in question and their classification according to various attributes. The paper will be useful to researchers, maintenance professionals and others concerned with maintenance to understand the importance of maintenance management
Details
Keywords
Mulatu Tilahun Gelaw, Daniel Kitaw Azene and Eshetie Berhan
This research aims to investigate critical success factors, barriers and initiatives of total productive maintenance (TPM) implementation in selected manufacturing industries in…
Abstract
Purpose
This research aims to investigate critical success factors, barriers and initiatives of total productive maintenance (TPM) implementation in selected manufacturing industries in Addis Ababa, Ethiopia.
Design/methodology/approach
This study built and looked into a conceptual research framework. The potential barriers and success factors to TPM implementation have been highlighted. The primary study techniques used to collect relevant data were a closed-ended questionnaire and semi-structured interview questions. With the use of SPSS version 23 and SmartPLS 3.0 software, the data were examined using descriptive statistics and the inferential Partial Least Square Structural Equation Modeling (PLS-SEM) techniques.
Findings
According to the results of descriptive statistics and multivariate analysis using PLS-SEM, the case manufacturing industries' TPM implementation initiative is in its infancy; break down maintenance is the most widely used maintenance policy; top managers are not dedicated to the implementation of TPM; and there are TPM pillars that have been weakly and strongly addressed by the case manufacturing companies.
Research limitations/implications
The small sample size is a limitation to this study. It is therefore challenging to extrapolate the research findings to other industries. The only manufacturing KPI utilized in this study is overall equipment effectiveness (OEE). It is possible to add more parameters to the manufacturing performance measurement KPI. The relationships between TPM and other lean production methods may differ from those observed in this cross-sectional study. Longitudinal experimental studies and in-depth analyses of TPM implementations may shed further light on this.
Practical implications
Defining crucial success factors and barriers to TPM adoption, as well as identifying the weak and strong TPM pillars, will help companies in allocating their scarce resources exclusively to the most important areas. TPM is not a quick solution. It necessitates a change in both the company's and employees' attitude and their values, which takes time to bring about. Hence, it entails a long-term planning. The commitment of top managers is very important in the initiatives of TPM implementation.
Originality/value
This study is unique in that, it uses a new conceptual research model and the PLS-SEM technique to analyze relationships between TPM pillars and OEE in depth.
Details
Keywords
As overall equipment effectiveness (OEE) is a metric to estimate equipment effectiveness of production systems, the purpose of this paper is to identify strategic management tools…
Abstract
Purpose
As overall equipment effectiveness (OEE) is a metric to estimate equipment effectiveness of production systems, the purpose of this paper is to identify strategic management tools and techniques based on OEE assessment of the ice cream production line.
Design/methodology/approach
This paper presents the collection and the analysis of data for ice cream production under real working conditions. The data cover a period of eight months. A framework process to improve the OEE of an automated production system was proposed. Six major stoppage losses, i.e. equipment failure, setup and adjustment, idling and minor stoppage, reduced speed, defects in the process, and reduced yield, were examined with the help of Pareto analysis. In addition, the actual availability (A), performance efficiency (PΕ) and quality rate (QR) measures, together with the complete OEE for each working day, week and month of the production line were shown.
Findings
The main goal of the study is to identify major stoppage losses, in order to examine and improve the overall equipment efficiency (OEE) of the ice cream production line through the application of an adequate management, i.e. TPM approach. Based on the obtained results, maintenance management strategy and production planning have been suggested to improve their maintenance procedures and the productivity as well.
Originality/value
The proposed method can be applied to each automated production system. The main benefits of this method are the improvement of productivity, quality enhancement of products, the reduction of sudden breakdowns and the cost of maintenance. Moreover, the analysis provides a useful perspective and helps managers/engineers make better decisions on the operations management of the line, and suggestions for improvement were proposed and will be implemented accordingly.
Details
Keywords
J.M. Simões, C.F. Gomes and M.M. Yasin
This research aims to examine the relevant literature related to maintenance performance measurement in the manufacturing sector. In the process, innovative approaches and models…
Abstract
Purpose
This research aims to examine the relevant literature related to maintenance performance measurement in the manufacturing sector. In the process, innovative approaches and models utilized to measure and manage maintenance performance in manufacturing operational settings are classified and examined. Based on this investigation, future research directions and themes are identified.
Design/methodology/approach
A database of 251 peer‐reviewed publications, published during the last 30 years, was utilized for the purpose of this research. The published works included contributions from both practitioners and scholars.
Findings
This literature review‐based research revealed important themes related to evolution of maintenance performance management. These themes focus on the effective utilization of maintenance resources, information systems support, and human factor management. Based on this literature review, a conceptual framework, which traces the different operational and organizational facets of the evolution of maintenance performance management, is offered.
Research limitations/implications
Based on the findings of this study, it is concluded that the area of maintenance performance and management is in need of more future systematic research efforts aimed at solidifying theoretical constructs and promoting the utilization of more practical applications.
Practical implications
Findings derived from this investigation have relevant manufacturing implications. In this context, understanding the different approaches to maintenance performance measurement and management, as utilized in manufacturing organizations, is critical to these organizations' performance improvement efforts.
Originality/value
Understanding the types and scopes of the different approaches and models utilized to manage and measure maintenance performance in manufacturing operational settings is important in light of the growing competitiveness of the manufacturing sector.
Details
Keywords
Mohamed Afy-Shararah and Nicholas Rich
Effective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor…
Abstract
Purpose
Effective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor efficiency measures sufficed when all that was made could be sold or when mass production systems filled warehouses with stock and the OMS had little relationship with “the consumer.” Modern manufacturing systems require a different form of flow optimization (beyond labor efficiency) measurement (Schmenner, 2015). The essential unit of measure for all OMS designs is the optimal use of time for process value adding and the flow of materials into and from the conversion process. Timely flow, therefore, satisfies the needs of multiple organizational stakeholders including cash flow (accounting), consumer reaction times (marketing) and the general steady state flow of materials (sales and supply chain). The purpose of this paper is to present the results of testing a new performance measure of operations flow effectiveness (OFE) with ten purposively selected cases.
Design/methodology/approach
The paper is theory building using ten, purposively selected, longitudinal case studies drawn from the UK high-value manufacturing (HVM) sector using a pluralist methodology of interviews, observation and secondary data.
Findings
The OFE measure provides a holistic view of material flow through the input-process-output cycles of a firm. The measure highlights OMS design weaknesses and flow inhibitors that reduce cash flow using a time-based approach to measuring OMS performance. The study validates the OFE measure and has identified six key design elements that enable high flow performance.
Originality/value
The paper tests a new process-focused flow performance measure. The measure supports a holistic approach to the manufacturing enterprise and allows different OMS designs to be evaluated so that organizational learning may be enacted to support performance improvement.
Details
Keywords
Overall equipment effectiveness (OEE) is a metric for estimating equipment effectiveness of the industrial systems. The purpose of this paper is to identify maintenance…
Abstract
Purpose
Overall equipment effectiveness (OEE) is a metric for estimating equipment effectiveness of the industrial systems. The purpose of this paper is to identify maintenance improvement potentials using an OEE assessment within the croissant production line.
Design/methodology/approach
The present work is carried out by analyzing the failure and repair data of the line. The failure data cover a period of 15 months. During this period the croissant production line usually operates over the entire day (24 h per day) in three 8-h shifts per day, and pauses at the weekends. Descriptive statistics of the failure and repair data for the line based on scheduled and unscheduled interruptions were carried. Moreover, the actual availability (A), performance efficiency (PE) and quality rate (Q) measures, together with the complete OEE for each working day for the croissant production line, were shown.
Findings
The main objectives are to understand the operation management of the croissant production line, and to measure the OEE characteristics in precise quantitative terms. OEE analysis can help the company to identify the primary problems concerning the A, PE and Q and acts immediately.
Originality/value
This paper presents a successful evaluation of OEE which will provide a useful guide to aspects of the production process, which identifies the critical points of the line that require further improvement through effective maintenance strategy (i.e. total productive maintenance). Moreover, the analysis provides a useful perspective and helps managers and engineers make better decisions on how to improve manufacturing productivity and quality.
Details
Keywords
The purpose of this paper is to develop a novel training material for the performance indicator overall equipment effectiveness (OEE) in the form of a game-based learning (GBL…
Abstract
Purpose
The purpose of this paper is to develop a novel training material for the performance indicator overall equipment effectiveness (OEE) in the form of a game-based learning (GBL) approach to be used in Industry and University context. The paper will present the development of the game as well as results from tests of the game with Industry employees and University students.
Design/methodology/approach
The data that are used in the game have been acquired from real OEE data logs of a reference company. The game has been refined iteratively using feedback from the participants of the tests.
Findings
The paper presents the game with its components and learning objectives. A comparison of various theoretical factors on GBL and the novel training material is performed and future improvements are suggested.
Research limitations/implications
The game has been developed based on OEE data logs from only one reference company.
Practical implications
The training material and specifically the game can be used to train Industrial workers and University students to better envision OEE as a performance indicator.
Originality/value
Serious games on lean manufacturing have been developed and played for a long time. While some of these games include OEE as an important result parameter, none really demonstrates how it is measured and analyzed.
Details
Keywords
Sagarika Raju, Harsha Arun Kamble, Rashmi Srinivasaiah and Devappa Renuka Swamy
The purpose of this research is to discover equipment losses and assess the accomplishment of overall equipment effectiveness (OEE) values.
Abstract
Purpose
The purpose of this research is to discover equipment losses and assess the accomplishment of overall equipment effectiveness (OEE) values.
Design/methodology/approach
Industries specialized in die shops often have issues regarding their efficiencies, conferring to statistics further production line department procedure for various machines frequently suffered restrictions owing to excessive downtime and speed losses in machines thus, reducing their effectiveness and efficiency. OEE is a means of determining how effective a piece of equipment is when in working condition. Calculation of OEE finds the heart of the issue and the root cause for the underlying problem.
Findings
The dimensional outcomes suggest that the average machine effectiveness has not attained the norm of >85%, but there is still room for progression.
Originality/value
One recommended procedure to reduce losses is to keep the actual pace of operation and downtime of equipment constant. Many such suggestions are provided to reduce the losses.