Brains & Solutions Consulting Group

OEE improvement

Enhance the Overall Equipment Effectiveness (OEE) and your productivity by implementing the appropriate tools and mechanisms to identify and deal with waste (MUDA) on a daily basis.

The OEE improvement in 3 basics: precise diagnosis, identification and classification of losses, and prioritization of solutions

For a relevant OEE improvement, get a proven methodical approach for identifying root causes and eradicating waste

BSC provides you with production and maintenance engineering support, enabling the identification of sources of waste and their impacts on your productivity.

The approach is comprehensive and innovative, as it draws from proven Lean tools and methods used in the most efficient manufacturing industries. Moreover, it incorporates a strategic prioritization concept that is tailored to your specific operational environment and operating context.

Our engineers will guide you through problem and waste identification, their qualification, and the implementation of effective solutions.

To find out all you need to know about the OEE improvement  : visit our Blog

Optimiser la productivité, le TRS et la performance

Have you identified the wastes that impact your productivity? We provide you with visibility into all the losses that undermine your processes and daily business

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Identification of wastes and losses: the 7 + 1 MUDA

Are you sure you’re getting all the wastes?

Wastages (MUDA) encompass all unnecessary activities and events that do not add value to the process, or that directly or indirectly hinder it.

Our mission is to help you identify them at every stage of your production process and to support you in developing and implementing appropriate solutions.

Overproduction

Often poorly understood or under-diagnosed, overproduction is the most impactful waste as it automatically triggers all other forms of losses. Moreover, it reflects the commitment of company resources to an unnecessary product.

We will help you identifying this waste, and deploying relevant solutions to bring your production closer to actual demand.

Waiting

Waiting times are among the most notorious losses within a company, as their effects are easily visible since they directly impact availability and production flow. These include downtimes due to equipment failures and those resulting from changeovers.

Although, the precise and comprehensive identification of these losses along with the implementation of suitable solutions remains less obvious. And that's precisely what we're here to help you with!

Motion

These losses typically result from inadequate workspace ergonomics, redundant or illogical procedures, or inappropriate organization and complex processes.

They include any unnecessary movement of people, equipment, or machines, tasks that require excessive motion, and repetitive actions that add no value.

Our external perspective on your processes and practices will will help you to identify and eliminate these performance-reducing superfluities.

Transportation

It mainly involves the transportation of materials, equipment, intermediate products, or parts contributing to the manufacturing of the final product. This category also includes empty trips, unnecessary movements between different sites, and unnecessary handling during the production phase.

By modeling the flows during the implementation of your processes, we can help preventing unnecessary transport. Similarly, we can help reducing and eliminating unnecessary transport by mapping the physical flows of existing installations.

Inventory

The concept of inventory here encompasses parts and products in waiting, as well as parts in transit.

Excessive inventory can result from over-purchasing, work in progress, or overproduction. It makes it challenging to detect certain losses such as waiting, as their impacts are mitigated by the surplus stock. This leads to a loss of space (retail space, infrastructure costs, etc.) and financial immobilization.

BSC will assist you in identifying the necessary and useful inventory for your process.

Defects

With our support, track down, eliminate and prevent defects throughout your production process.

Non-quality usually results in extra work for corrections or, worse, generates waste. In either case, poor quality or defective parts consume valuable time and incur direct financial costs for companies, which are not always under control. Moreover, it can have a lasting impact on the company's reputation, with all the associated consequences.

Over-processing

Although quite common in businesses and production facilities, over-processing is a subtle and challenging form of waste to identify, especially for the people involved in the process.

It consists of producing more work, adding more components, or including more steps in the manufacturing process of a product, or in the process of delivering a service, than what is necessary for the customer or expected by them.

In manufacturing, this may include using equipment with a higher precision for a simple work, or using higher-capacity components to manufacture a basic product. 

Non-Utilized Talent

Under-utilization, misutilization or non-utilization of people's skills is a real source of waste, because it is generally not quantified and has a hard-to-perceive impact on the product or service delivered to the customer.

For example, in the manufacturing industry, this could manifest as not leveraging field experience feedback or the expertise of workers who are typically confined to execution tasks.

BSC will help you set up processes to capitalize on the skills of all your employees, at every level of your organization.

Let's discuss your operational challenges And we will provide you with the technical solutions to overcome the obstacles to your performance.

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Loss qualification

What if you weren’t addressing the most impactful losses in your process?

The loss qualification phase is by far the most decisive in the OEE improvement process. Indeed, it is at this stage that wastages are quantified and categorized, enabling their prioritization and, most importantly, the identification of the most relevant tools for each issue.

BSC approach is based on the following points:

  • Gemba Walks: They will primarily enable the identification of all types of losses and their impacts.
  • Thorough collection of operational data: Reliable and concrete data will be necessary to quantify losses, quantify gains for the company, but above all, measure performance and changes.
  • Categorization and prioritization of losses: Categorized and prioritized losses allow for the proper selection of tools and methods for problem resolution, as well as the streamlining of efforts.

The entire value of our support lies in comprehensively identifying the components of these losses and providing you with tailored optimization solutions.”

OEE improvement - Loss classification

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Industrial asset prioritization

How do you determine the equipment or production lines on which you prioritize your actions and efforts?

Very often, manufacturing companies direct their efforts (material, financial and/or human) towards specific equipment, lines or sectors, based solely on criteria linked to production needs, or on the perceived reliability of the equipment (“this equipment breaks down ‘too often’, so it should be a priority to work on it”).

The P2Mi (Multi-criteria Prioritization of Industrial Means) approach offer by BSC makes the decision-making and the adoption of investment as well as the operational resource engagement strategies more relevant, as it is based on a comprehensive risk analysis integrating all the components (technical, qualitative, environmental and financial) that contribute to industrial performance.

Based on a grid of over 100 weighted criteria related to production (performance), quality, maintenance (availability) and HSE constraints, the site’s equipment are ranked according to different levels of criticality. A breakdown of these raking according to resource allocation then provides a relevant prioritization that reflects all operational constraints in addition to financial aspects.

What?

The P2Mi* is a risk analysis approach to assess the criticality of industrial assets.

*P2Mi: (Priorisation Multicritère des Moyens Industriels) – Multicriteria Prioritization of Industrial Means

Why?

Identify and prioritize the most critical equipment, identify appropriate solutions, streamline efforts, resource allocation and investments

How?

Evaluation of each equipment based on weighted criteria of Production, Quality, Maintenance, Safety & Env., and Costs.

P2Mi approach

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Solutions

Which solution for which loss?

Lean methods and tools are well known for their effectiveness, and are the key to solving most of the wastage and loss of performance. However, the sustainability of these solutions relies on human involvement and the teams’ ownership of them.

In addition to implementing these solutions, we help you in rethinking your best practices, from mindset to the environment in which they are applied, thus focusing on the sustainable adoption of behaviors that will perpetuate the gains made and their positive impacts.

This is why our support is generally structured around collaborative workshops in which groups of participants (including your staff) are involved in developing solutions.

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