Evaluation and Improvement of a Plastic Production System Using Integrated OEE Methodology: A Case Study

Overall equipment effectiveness (OEE) is a key indicator to measure the effectiveness of production systems. This paper aims to evaluate and improve a plastic production line based on OEE evaluation. An integrated framework is proposed to enhance the production system efficiency. This paper presents the data for a Plastic production line in Jordan under real working conditions. The data covers three months. A framework process to improve the OEE of the Plastic production system was proposed. Six major stoppage losses were inspected with the help of Pareto analysis. Furthermore, the actual availability, efficiency, and quality rate measures, together with the whole OEE for each working day, week, and month of the production line were shown. The methodology is based on determining the OEE of a Plastic production line after determining the causes of failures. The fishbone diagram tool is used to determine the root causes of failures. To improve the OEE measure, several losses are identified. The results reveal that the company should improve its policy to improve the production line’s performance and reduce losses. Top management should also pay attention to reducing the speed losses, which consist of 58.1%, and eliminate the planned and unscheduled disruptions covering 12.73% of all losses. This can be achieved by establishing a proper operation management procedure and strategy. This, in turn, optimized the equipment’s effectiveness. The quality procedure should include the changeover program that may be executed every day. Similarly, all preventive maintenance procedures for the six machines should be properly executed in predetermined intervals. There are several limitations in the research. Firstly, the research case study is only the plastic production system. Secondly, the research is related to the downtime or stoppage by analyzing it using fishbone diagram. Further, supported by other techniques such as the Pareto chart, six big losses analyses and CED. This research conducted on a Plastic industry. However, similar studies can be carried out in future in other manufacturing industries like electronic, pharmaceutical, textile industries, etc., and service industry. However, as future research work the contributions of this paper with other lean manufacturing concept like six sigma, quality function deployment, TQM, and just-in-time manu-facturing, can also be conducting to assess the overall production line efficiency. On the other hand, several statistical tests can be implemented based on data collected of TPM performance indicators. The proposed method supports policymakers in their decision-making process on the operations management line. Further-more, it improves the production systems’ productivity quality, and performance, reducing unplanned stop-pages and breakdowns, and reducing maintenance costs.