Case studies

Context

OEE was calculated in a spreadsheet by each shop manager, with different definitions from one site to the next. No comparison was possible and short stoppages escaped measurement entirely.

Solution

Controller data capture on 22 lines, a downtime cause dictionary shared by the three sites, OEE computed in the MES and shop floor screens refreshed every minute. Piloted on one line for ten weeks before roll-out.

Results

• OEE up from 61 % to 74 % within twelve months
• Short stoppages finally visible: 31 % of lost time
• Production meeting cut from 45 to 15 minutes

Context

The paper batch record tied up two full-time staff on review and delayed batch release by several days. Deviations were caught too late to be corrected.

Solution

Electronic batch record integrated into the MES, blocking checks at critical steps, 21 CFR Part 11 compliant electronic signature and an interface with the LIMS for analytical results.

Results

• Release time cut from 6 days to 36 hours
• Zero documentation findings at the latest audit
• Review effort down from 2 FTE to 0.4 FTE

Context

A raw material alert meant blocking a full week of production, because incoming batches could not be linked precisely to dispatched pallets.

Solution

Unique container identification, upstream and downstream traceability in the MES, a WMS interface for stock movements and an on-demand recall simulation.

Results

• Recall scope reduced by 90 %
• Batch genealogy retrieved in under 2 minutes
• Cycle count accuracy raised to 99.4 %