Tracking and recordkeeping of paper-based OEE reports can be a tedious task for quality managers in manufacturing facilities. Using mobile-ready OEE report templates can help easily identify causes of lost production, monitor overall equipment effectiveness, and enhance output capability and product quality.
This article features:
- ways to minimize the “six big losses” of OEE manufacturing;
- a mobile app to ensure overall equipment effectiveness; and
- free OEE report templates you can download, customize, and use.
The greatest hindrance to increasing overall equipment effectiveness is the Six Big Losses—unplanned downtime (equipment failure), planned downtime (setup and adjustments), small stops (idling and minor stops), slow cycles (reduced speed), production rejects (process defects and rework), and start-up rejects (reduced yield). Here are 5 simple ways quality managers, cross-functional teams, and upper management can minimize the Six Big Losses:
- Observe breakdown patterns
Availability is one of the three factors that determine overall equipment effectiveness. If equipment failure recurs, production time is lost and quality output is decreased. Quality managers should regularly record breakdown incidents, analyze when they most frequently occur, and identify their root cause(s). Seeing real-time data and actionable insights provides quality managers and upper management the visibility needed to make wise business decisions and achieve operational excellence.
- Maximize scheduled downtime
During planned equipment maintenance, manufacturing technicians should also perform cleaning, calibration, and tooling adjustment. Quality managers should consider what continuous improvement activities they can do such as a 5S Audit, Gemba Walk, etc. Scheduling quality inspections during planned downtime helps redeem production time while ensuring the manufacturing process produces conforming, safe, and quality products.
- Empower machine operators
When the equipment works but manufactures output at a slower rate than expected, wrong machine settings and a manufacturing process-caused bottleneck could be the culprit in holding up production. Empower machine operators with a digital checklist app to easily follow correct machine operation and start-up and shut-down procedures, document minor stops, and mitigate idling. Enable manufacturing technicians to completely, accurately, and efficiently perform equipment maintenance with a digitized machine maintenance checklist.
- Improve workplace practices
Most performance losses (speed losses) occur because of the lack of investment in machines and poor maintenance planning. Cross-functional teams, including upper management, should assess equipment investment plans, production volume, and cost using an OEE manufacturing checklist. For every failed response to questions such as “Is equipment closely monitored in the start-up stages?” and “Are plant assets properly managed?”, assign corrective actions to immediately address quality issues, improve workplace practices, and build a culture of accountability.
- Automate manual tasks
Scrap or damaged products during normal production or due to adjustments made during start-up can be prevented when manufacturers streamline quality monitoring checks. Accessing quality assurance inspection forms anywhere, any time, and on any iOS, Android, and Windows mobile device allows manufacturing personnel to save time checking products and preparing reports. Quality managers should also take advantage of a mobile-ready OEE report template for more efficient collection of data on overall equipment effectiveness.
iAuditor, the world’s most powerful inspection checklist app, can help manufacturing technicians ensure prompt and proper equipment maintenance, quality managers report and monitor overall equipment effectiveness, and upper management benchmark production assets to industry standards. With iAuditor, you can:
- Create mobile-ready OEE report templates. Request a demo.
- Send real-time notifications for scheduled inspections and corrective actions
- Capture photo evidence of the Six Big Losses
- Automatically generate and share OEE reports to members of your organization. Preview sample report.
- Use for free with small teams. Unlimited reports and storage for premium accounts. Compare pricing plans.
Mobile-ready OEE Report Templates
OEE Manufacturing Checklist
This OEE Manufacturing Checklist aims to help cross-functional teams, including upper management, evaluate the overall equipment effectiveness of the manufacturer. Use this OEE manufacturing checklist to assess the current equipment investment plans and maintenance planning, production volume, scheduling, quality, and cost. Assign corrective actions to immediately resolve overall equipment effectiveness issues and customize this OEE manufacturing checklist to fulfill specific company requirements.
Machine Maintenance Checklist Template
A machine maintenance checklist template is used by manufacturing technicians in performing scheduled equipment maintenance in the manufacturing facility. This machine maintenance checklist template has been designed to make it easier for manufacturing technicians to adjust, fix, or clean equipment and select cases when equipment diagnosis techniques are used such as cracking, corrosion, or loosening. Add notes or relevant photos for objective evidence of prompt and proper machine maintenance.