Manufacturing productivity analysis by applying overall equipment effectiveness metric in a pharmaceutical industry

Abstract

Improving the productivity of a manufacturing firm is very imperative in order to obtain high profits in such a competitive market. Equipment is an important part of a manufacturing system and its efficiency directly affects the quality and cost of the product contributing to overall productivity of a manufacturing plant. This paper focuses on calculating the overall equipment effectiveness (OEE) at a local pharmaceutical industry and investigates the key factors which influence the overall equipment effectiveness. OEE is an important tool which identifies areas that may have bottleneck in the production line, covering three major aspects such as the availability, performance, and quality rate of the output of equipment. On the basis of OEE, six significant losses were identified. The preliminary results of the analysis showed that OEE for the dry suspension (D/S) section is only 23% which is substantially below the benchmark of OEE level i.e. 85%. The results also presented that prime cause involves a high difference between the performance level of world class and dry suspension (D/S) process which is due to unavailability of machines for a longer period of time and malfunctioned machines producing products in large quantities that need to be

A New Scoring Approach to Calculate Overall Equipment Efficiency: A Case Study

“…When the studies on OEE in the literature are examined, it is realised that some of these studies are aimed at understanding the structure of OEE (da Costa and de De Ron and Rooda, 2005;Jeong and Phillips, 2011). Nevertheless, it is seen that the literature is dominated by OEE case studies carried out in various sectors and industries; for instance, pharmaceutical industry (Zubair et al, 2021), electronic components industry (Fam et al, 2018), automotive and engineering industry (Dal et al, 2000;Jiang et al, 2011;Šajdlerová et al, 2020), plastic processing industry (Slaichová and Marsíková, 2013), machinery industry (Xiang and Feng, 2021). Moreover, Munchiri and Pintelon ( 2008) conducted a literature review in order to compare different performance metrics (OEE, TEEP, Overall Factory Effectiveness, Overall Plant Effectiveness, Production Equipment Effectiveness, and Overall Asset Effectiveness).…”

“…OEE reveals how well a production unit is performing during the scheduled period (Zubair et al, 2021). It can be expressed as the ratio of the valuable operating time to the loading time.…”

Desempenho de processos de compressão: Avaliação do uso de simulador de compressão para caracterização de deformação de excipientes e a aplicação de modelagem multinível em linhas produtivas

“…Já o termo qualidade relaciona produção defeituosa e rendimento reduzido dos lotes (Zubair et al, 2021). Assim, essas perdas garantem que a produção real nunca será igual à produção teórica, se o índice OEE for menor que 1 (Carlo;Arleo;Tucci, 2014).…”

“…Também pode promover ações precoces para evitar problemas e melhorar o desempenho das linhas de produção, além de ser utilizado para entender os parâmetros críticos do processo e identificar as causas-raízes dos desvios, direcionando, novamente, as ações a serem aplicadas. Considerando os estudos de OEE na indústria farmacêutica, há diversas revisões sobre o impacto das ações nos índices de OEE, e como isso afeta a implementação da Manutenção Produtiva Total (TPM) nas empresas (Ramachandra et al, 2016;Zubair et al, 2021). Chikwendu, Chima e Edith (2020) destacaram que a força dos índices OEE tornando as perdas mais transparentes e evidenciam áreas de melhoria e redução de perdas e custos de processos.…”