Facing a capacity crunch? Before buying new machines, unlock hidden potential in existing assets. Operational Efficiency blends SMED, TPM, and line balancing to boost throughput by 15–30 % with zero capital expenditure.
| Area | Typical Loss |
|---|---|
| Changeovers | 20–60 minutes each |
| Downtime | 10–15 % OEE hit |
| Unbalanced lines | Idle and overburden stations |
| First-pass yield | Below 90 % |
| Stage | Key Actions | KPI Impact |
|---|---|---|
| Study | Gemba walks, cycle-time capture, constraint analysis | Identify top 20 % losses |
| Improve | SMED kits, TPM checklists, takt-time balancing | Capacity gain 15–30 % |
| Control | Hour-by-hour boards, layered audits | Sustain OEE above 80 % |
| KPI | Baseline | Target |
|---|---|---|
| Overall equipment effectiveness | 58 % | ≥ 80 % |
| On-time in-full (OTIF) | 76 % | ≥ 95 % |
| Overtime hours | — | − 25 % |