Manufacturing OEE Assessment

Unlock the full potential of manufacturing productivity by accurately measuring and enhancing Overall Equipment Effectiveness (OEE). Manufacturing businesses seeking to understand levels of productivity, efficiency, effectiveness, and cost, as well as how to benchmark these metrics against industry peers, partner with Catalant’s OEE Experts who have deep expertise running these assessments to:

Increase production efficiency and reduce downtime

Gain enhanced visibility into operational performance

Identify key levers for performance improvement

Approach & Deliverables

A Comprehensive Manufacturing Assessment Solution Designed for Impact

Our team of 1–3 experienced operations Experts will conduct an in-depth analysis of data from your manufacturing operations and carry out onsite observations of production activities within selected processes over a 1–2-day period.

01

Assess OEE/OPE performance

Obtain an OEE/OPE breakdown from the main process’ bottleneck and pacemaker(s).

02

Determine improvement levers

Identify the main improvement levers by category, following the standard OEE breakdown nomenclature.

03

Develop and execute an improvement implementation plan

Create a detailed action plan outlining the activities required to convert improvement levers into targeted initiatives that will enhance OEE/OPE.

Winning Together

Manufacturing Assessment in Action

Tier One Automotive Supplier
More Success Stories

Problem

A Private Equity company acquired a Tier One Automotive Supplier facing fierce competition due to low productivity and high costs.

Action

A diagnostic was conducted and identified key issues in labor productivity, indirect materials, and scrap. This lead to: 

  • The creation of an improvement transformation team to address opportunities in Manufacturing, Maintenance, Industrial Engineering, and Procurement functions
  • Identification of 20-25 initiatives that would deliver results within 6-10 months

Results

After a 3-month implementation focused on improving OEE, the client achieved: 

  • 10% increase in production output
  • Reduced changeover lead time by 50% by using SMED
  • KPIs and detailed routines for supervisors that helped optinize machine speed and minimize unplanned interruptions

Plastics Manufacturing Turnaround

A consumer goods enterprise faced high operations costs and low OEE. Eight key project initiatives were identified to improve OEE and decrease costs. This led to the facilitation of eight cross-functional teams to address downtime, scrap, and cycle time losses, in addition to the implementation of a manufacturing performance system. As a result, OEE improved from 65% to 83% and the company realized annual savings of $5MM.

Maintenance & Reliability Improvement

A large Pharma-Chemical client was facing increased maintenance costs alongside declining asset performance. They wanted to improve fixed costs and maintenance and engineering performance, but the executive team was not aligned on where to allocate resources. After undergoing an OEE assessment of equipment criticality involving maintenance, engineering, and operations departments, they gained standardized metrics and effective fund allocation.

Featured Manufacturing Assessment Experts

Featured Manufacturing Assessment Experts

Yorgos F.

20+ years of experience in manufacturing and transformation

Former McKinsey Associate Partner with 10 years of operating experience at Rolls-Royce and Toyota. Expertise includes manufacturing, production, maintenance, procurement, and supply chain.

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Michael F.

25+ years of consulting and operating experience focused in strategic operations and Lean Six Sigma

Former McKinsey consultant with key skills including strategic alignment/planning, leadership coaching, continuous improvement cost reduction, and margin enhancement.

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Chad B.

25+ years of experience in operational excellence manufacturing

Former Deloitte consultant with 10+ years of operating experience at IBM and AlixPartners. Expertise includes process improvement, lean enterprise, Six Sigma, materials, and program/project management.

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