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 #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! 🤪 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 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? 🤔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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