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Top 10 sources of OEE losses

These are the first areas to consider to improve your operation's Overall Equipment Effectiveness.

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Paul Zepf of Zarpac Inc., a leading packaging industry authority in Overall Equipment Effectiveness, shared his OEE process improvement list at recent Packaging Performance Workshops (see below for more information).

Based on Zepf's 35 years of related industry experience, these are the Top 10 sources of OEE losses he has identified at packaging operations:
1. Losses due to lunch period time, lunch overage times, production run down before lunch and production run up after lunch.
2. Losses due to break period time, break overage times, production run down before breaks, and production run up after breaks.
3. Losses due to meeting period time, meeting overage times, production run down before meeting (if applicable), and production run up after meetings (if applicable).
4. Losses due to shift changes, production run down before shift changes and production run up after shift changes.
5. Losses due to extent and frequency of major changeouts.
6. Losses due to minor changeouts.
7. Losses due to purge at the end of a given production run.
8. Losses due to the difference in speed actually run on the production line versus what should have or could have been run based on the original design of the line and its tested capability.
9. Losses in hierarchical order of the downtimes of each machine.
10. Losses due to wastage, including all material costs, labor costs, ergonomic costs, bins or cart costs, holding area costs, transfer costs, and disposal costs.

We plan to provide the next 11 along with other OEE insights from Zepf in upcoming issues of Packaging Insights.

For further information, visit and check out the next Packaging Line Performance Workshop sponsored by Packaging World, ELAU, Hartness Intl., and Multivac. The next workshops are slated for June 24-25 in Los Angeles and Sept. 16-17 in New Brunswick, NJ.
-Rick Lingle

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