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Common Culprits Causing Low OEE on Packaging Equipment Lines

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There are a many ways you can drag down your Overall Equipment Effectiveness (OEE) rating, but make sure you avoid these common culprits…

1. Under training. Machine operators should know how to properly load commodities and quickly clear jams to get the line back up and running. Train them accordingly, and place simple how-to instructions–with more pictures and less text–near the machines for fast cleaning, troubleshooting and changeovers.

2. Shoddy commodities. Stay on your vendors to ensure they provide quality commodities. Inconsistent and out-of-spec materials are hard on equipment and are big-time OEE drags. By optimizing your commodities, you’ll make it easier for the equipment to run smoothly. The extra cost–usually just pennies–is worth it.

3. Lack of buffer zones. Strategically place buffers to compensate for downstream failures while the upstream equipment, which can be more difficult and time-consuming to restart, continues to operate. It’ll help reduce labor costs and overtime and could increase your line capacity.

4. Out-of-synch speeds. Making sure that downstream equipment outpaces upstream machines seems like a no-brainer, yet we still see lines in which equipment speeds are not properly synchronized. Each successive machine must outpace its predecessor, or it’ll pull down your OEE rating.

5. Surge charges. Improper spacing of equipment can trigger harmful surges, shutting down upstream equipment unnecessarily. Be sure you’ve got enough surge coverage and that the location of sensors allows for an efficient run.

6. Excessive “reject” stops. Your OEE rating gets nicked with every stoppage, so tread carefully here. Plan for a “reasonable number” of items to come off the line without a shutdown. Rethink what’s truly a critical error–and worthy of a stoppage– and what isn’t.

7. Refill shutdowns. Don’t let new web rolls, labels, and tape put a halt to your run. Work with your OEM to allow refill changes to be made online, and keep things flowing.

Our firm:

MGS Machine serves the pharmaceutical market with its automated packaging machinery solutions. We have over 14,000 successful installations in 27 countries around the world. Our main campus is located in Maple Grove, MN USA. We work with pharmaceutical manufacturers and their contract packaging suppliers to implement automated secondary packaging lines.

MGS Machine Corporation

9900 85th Ave N.

Maple Grove, MN USA 55369