OEE Six Big losses #6 The Start up Defects

OEE Six Big losses #6 The Start up Defects

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6 key losses -The start up Defects Understanding Start-Up Rejects in OEE: A Hidden Quality DrainWithin the framework of Overall Equipment Effectiveness (OEE), Quality stands as one of the three core pillars, alongside Availability and Performance. While many manufacturers focus on production-time defects, a less-discussed yet equally critical source of quality loss is the Start-up Reject—a type of defect that occurs immediately after a machine or line begins operation. What Are Start-Up Rejects?Start-up rejects are defective units produced during the initial phase of machine operation—either at the beginning of a shift, after a changeover, or following maintenance or equipment downtime. These are not incidental flaws; they are often symptomatic of deeper inefficiencies in the warm-up or ramp-up phase of production.These defects usually happen because machines, tools, or processes haven't reached optimal operational conditions. Factors like temperature stabilization, incorrect calibration, residual materials, or operator oversight during start-up can all contribute to this issue. Why Start-Up Rejects MatterAlthough they might seem insignificant in isolation, start-up rejects...
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OEE 6 Big losses #5 The production Defects

OEE 6 Big losses #5 The production Defects

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OEE 6 Big Losses - The production Defects The Power of OEE The beauty of OEE (Overall Equipment Effectiveness) lies in its comprehensive nature—it encapsulates all the essential components that define a meaningful key performance indicator (KPI) in manufacturing operations.Among the three core components of OEE—Availability, Performance, and Quality—Quality plays a critical role. Without producing a high number of good-quality units, speed and efficiency become irrelevant. No matter how fast or uninterrupted your production is, if the output is flawed, it diminishes the overall value. The beauty of OEE (Overall Equipment Effectiveness) lies in its comprehensive nature—it encapsulates all the essential components that define a meaningful key performance indicator (KPI) in manufacturing operations.Among the three core components of OEE—Availability, Performance, and Quality—Quality plays a critical role. Without producing a high number of good-quality units, speed and efficiency become irrelevant. No matter how fast or uninterrupted your production is, if the output is flawed, it diminishes the overall value.One of the "Six Big...
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OEE 6 big losses #4 The small Stop

OEE 6 big losses #4 The small Stop

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OEE 6 Big losses -The Small Stop While it is SMALL, it can also be very BIG! đŸ€Ș There we go again ... 6 Big OEE losses #4-The Small Stop Best way to understand small stop is like traveling on a journey towards a destination, along the way, you are estimating to reach the destination say in 1 hour, along the roadyou bump into a traffic jam, road blockages, accidents etc. These are the small stops. In the production process, minor disruptions often occur due to waiting for materials to run, delay in restarting machines after the disruption, equipment misalignment, or jam-ups. These are the common small stops that we have been focusing on.Some advance processes have built-in functions that detect the cause of these stops. These systems may rely on Stack light indicator or internal controller like PLCs to detect error codes related to the disruption. Why are these small stops important? As you know when the production is running 24 hours daily,...
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Six Big Losses #3 -The Slow Cycle

Six Big Losses #3 -The Slow Cycle

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Six Big Losses in OEE #3 The Slow Cycle SLOW --> BIG !😉 Why? When it is concerning the heartbeat of the production, so it is BIG!🧹The 6 Big losses #3 -The Slow Cycle.In any manufacturing environment, cycle time is more than just a metric—it's the heartbeat of the production system. Each completed cycle represents a unit of output, and when those beats slow down, so does productivity.That’s why monitoring cycle time is so critical. It tells you, in real time, whether your production line is healthy and performing at its best—or if there are hidden inefficiencies slowing things down.When you walk through a modern production floor, you’ll often see digital boards displaying Target Output vs. Actual Output. This real-time feedback loop creates operator awareness, helping them stay aligned with expected production goals. It also acts as a subtle productivity cue, letting teams know if the "heartbeat" of the process is slowing.This slowdown—known as a slow cycle—can be caused by...
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Six key losses in OEE -The Planned Stop

Six key losses in OEE -The Planned Stop

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The Planned Stop - Six OEE Big Losses We can understand unplanned downtime, but why planned stop? đŸ€”In manufacturing, planned stops represent a major category of production losses and it is part of the OEE six big losses. These are intentional halts in machine operation—such as for model changes, tool changes, or scheduled maintenance—that can heavily impact OEE (Overall Equipment Effectiveness) if not managed properly.A key tool in managing and visualizing these stops is the Andon system—a real-time visual indicator (typically using stack lights with 3 or 4 colors) that communicates machine or process status directly from the production floor. A red or blue light, for instance, may signal a planned stop, alerting operators and maintenance teams in real time.While planned downtime is necessary, poor planning or execution can erode process availability and drag down your OEE score. That’s why tracking and optimizing these stops is vital.Common Causes of Planned Stops:* Model or Tool Changes – Switching between product variants requires precise...
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The 6 Big Losses in OEE – Deep Dive into Unplanned Downtime

The 6 Big Losses in OEE – Deep Dive into Unplanned Downtime

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The 6 Big Losses in OEE – Deep Dive into Unplanned DowntimeIn the world of manufacturing, where efficiency defines competitiveness, OEE (Overall Equipment Effectiveness) serves as a critical performance benchmark. Among the six major losses that OEE identifies, Unplanned Downtime stands out as a particularly disruptive and costly factor — especially in modern, automated environments.Let’s take a closer look at what unplanned downtime really means, its cascading effects on operations, and how manufacturers can tackle it more effectively using predictive AI-powered maintenance.What Is Unplanned Downtime?Unplanned downtime refers to any unexpected stoppage of production caused by equipment failure or unforeseen malfunctions. Unlike scheduled maintenance or planned shutdowns, these interruptions catch production teams off guard — causing a sudden halt in operations and often requiring emergency repairs or adjustments.With today's increasing reliance on automation, the risks associated with unplanned downtime have multiplied. For manufacturers operating under lean principles or Just-in-Time (JIT) strategies, even a short delay can have a "cabin effect" — where a minor...
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Understanding the Six Big Losses in Manufacturing: A Roadmap to Greater Efficiency

Understanding the Six Big Losses in Manufacturing: A Roadmap to Greater Efficiency

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Understanding the Six Big Losses in Manufacturing: A Roadmap to Greater EfficiencyWhen you step onto a production floor, you’re immediately immersed in an atmosphere of intensity and focus. It’s a space where every individual, machine, and process is aligned with a singular purpose: maximizing output. Love it or not, this relentless pursuit of efficiency forms the core of manufacturing operations.In this high-pressure environment, companies rely on metrics to track and enhance productivity. Among these, one metric stands out as the gold standard: Overall Equipment Effectiveness (OEE). OEE is a universal benchmark in manufacturing, measuring how well a production process performs using the formula:OEE = Availability × Performance × Quality.This formula distills productivity into three essential components, providing a comprehensive view of where improvements can be made. The concept of OEE was introduced by Seiichi Nakajima, a visionary in manufacturing and the creator of the Total Productive Maintenance (TPM) system in the 1960s. His work laid the foundation for Japan’s global...
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AIoT power management and optimization

AIoT power management and optimization

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Applying Industrial IoT and AI in power measurement and optimization Introduction to Power Measurement with Industrial IoT and AI in Predictive Power ManagementIn today's rapidly evolving industrial landscape, effective power management is crucial for optimizing operational efficiency, reducing costs, and minimizing environmental impact. Traditional methods of power measurement and management often fall short in providing real-time insights, predictive capabilities, and the adaptability needed to address the complexities of modern industrial environments. This is where Industrial Internet of Things (IIoT) and Artificial Intelligence (AI) come into play, revolutionizing the way industries monitor, manage, and optimize their energy consumption.Power Measurement with Industrial IoTThe Industrial Internet of Things (IIoT) refers to the integration of interconnected sensors, devices, and systems within industrial settings, enabling the collection and exchange of vast amounts of data in real time. When applied to power measurement, IIoT allows for the continuous monitoring of electrical parameters—such as voltage, current, power factor, and energy consumption—across various equipment, machinery, and processes.Key benefits of...
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How is Malaysia’s Second Economic Takeoff Connected to Technological Advancements?

How is Malaysia’s Second Economic Takeoff Connected to Technological Advancements?

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"During the 'Jom! Let's Sembang AIoT' session, we kicked off our discussion with topics related to Malaysia's New Industrial Master Plan 2030 (NIMP 2023) and a newly published book by the Deputy Minister of Investment, Trade, and Industry, Mr. Liew Chin Tong.The concept of a 'second takeoff' highlighted in this book caught my attention during one of his interviews with a media outlet, mentioned Mr. CC Lee, the Founding Director of AIOTMission Sdn Bhd, during the live session.Since we have not yet received the book, we’ll wait for its arrival to provide more commentary and insights from its content later. Our primary interest in examining the book is due to the significant factors it presents that are crucial to our economy and closely tied to the adoption of technologies like AI and IoT.To begin, let's take a closer look at the key goals of the NIMP 2030, recently announced by our Prime Minister." Key goals of the NIMP 2030 plugged...
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Industrial Transformation with LLM and AIoT

Industrial Transformation with LLM and AIoT

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Chat GPT and Gemini the top two Gen AI LLM platform Today, we are discussing two major LLM (Large Language Model) Gen AI platforms namely Chat GPT and Google Gemini and their potential to drive industrial transformation in the near future.LLM Gen AI is poised to play a crucial role in various aspects of industrial transformation, particularly in processes that require optimization and improvement. These platforms will be instrumental in data analytics, where machine learning and deep learning AI models are applied.Given the rapid advancements in LLM Gen AI development, it is only a matter of time before these platforms take on the responsibility of seamlessly integrating AI models. This will enable end-to-end solutions, connecting data analytics with LLMs to deliver comprehensive outcomes.  What is industrial Transformation? Industrial transformation refers to the comprehensive process of adopting advanced technologies, digitalization, and new business models to fundamentally change the way industries operate.This transformation aims to enhance efficiency, productivity, flexibility, and sustainability across the value chain....
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