First steps
- Record stops with reason codes for 2 to 4 weeks.
- OEE by machine, Pareto of stop minutes.
- Attack the top loss with a small team.
How to measure success
OEE (%), MTBF and MTTR. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- OEE analysis: Manual processes without a machine cycle.
- Pareto chart: A single defect type with one known cause.
- TPM: One-off breakdowns with a known cause.
- SMED: Lines that rarely change over.
- 5 Why: Problems with many interacting causes; use data and DOE there.
- 5S: Process capability problems.
The methods in one line
| Method | What it is |
|---|---|
| OEE analysis | Splits equipment losses into availability, performance and quality to show where time is lost. |
| Pareto chart | Ranks defect types or causes so the team works on the vital few first. |
| TPM | Total productive maintenance: operator care, planned maintenance and loss elimination. |
| SMED | Shortens changeovers by moving work outside the machine stop and simplifying the rest. |
| 5 Why | Ask “why” until you reach a cause you can act on, with one chain for occurrence and one for escape. |
| 5S | Workplace organisation: sort, set in order, shine, standardise, sustain. |