From data to efficiency

At a glance

This anonymized case shows how a factory used OptiPeople Data Platform data to uncover efficiency opportunities, improve OEE, and make a better-informed equipment investment.

The core result was an increase in OEE from 21% to 41%.

The situation

The machine in focus produced both small and large series sizes.

Because changeovers were expensive, the factory suspected there was room for improvement, but lacked the data needed to make confident decisions.

OptiPeople Data Platform was introduced to create that decision basis.

What the data showed

Once data collection began, it became clear that the machine's productivity was closely linked to series size.

The many changeovers were a major cause of low efficiency. Smaller series absorbed too much time in setup and reduced overall performance.

Service checks also played a role. After checks in October and February, OEE moved to a higher level.

How the improvement was created

The analysis showed that it made sense to buy an additional smaller machine for small elements.

That smaller machine had no setup time, even though it produced more slowly than the larger one. For small series, it was still the better choice.

After the investment, the factory no longer depended on one machine that spent too much time idle or in setup mode. Instead, it had two machines better suited to different production patterns.

Why the analysis mattered

An important insight was that OEE had to be evaluated by series size, not only at machine level.

One machine can perform well for some product types while being dragged down by others. Without that level of detail, it is easy to reach the wrong conclusion.

In this case, the strongest OEE results appeared in the series sizes where 500 items or more were produced before changeover.

The result

The factory saw several measurable gains:

• OEE improved from 21% to 41%
• 6,119 units could be produced in 2.3 shifts instead of 3.0 shifts
• daily production time for that volume dropped from 24 hours to 18.5 hours
• that corresponds to a saving of 5.5 hours per day

The business case

Two payback perspectives were considered.

Using a fixed-cost approach, a total investment of DKK 3.5 million and an annual saving of DKK 750,000 produced a payback time of 4.6 years.

Using an earnings-maximization approach, the additional production capacity was valued at DKK 2.96 million per year. If that extra output could be sold, payback time was 1.2 years.

Key takeaway

The case shows that production optimization starts with data.

When the right level of detail is available, it becomes possible to improve service routines, adjust production strategy, and evaluate investments on a much stronger basis.