Skip to main page content
U.S. flag

An official website of the United States government

Dot gov

The .gov means it’s official.
Federal government websites often end in .gov or .mil. Before sharing sensitive information, make sure you’re on a federal government site.

Https

The site is secure.
The https:// ensures that you are connecting to the official website and that any information you provide is encrypted and transmitted securely.

Access keys NCBI Homepage MyNCBI Homepage Main Content Main Navigation
. 2020 Apr 18;6(4):e03796.
doi: 10.1016/j.heliyon.2020.e03796. eCollection 2020 Apr.

The optimization of overall equipment effectiveness factors in a pharmaceutical company

Okpala Charles Chikwendu  1 , Anozie Stephen Chima  1 , Mgbemena Chika Edith  1
Affiliations

The optimization of overall equipment effectiveness factors in a pharmaceutical company

Okpala Charles Chikwendu et al. Heliyon. .

Abstract

Over the years, the inability of pharmaceutical companies to achieve optimum maintenance of their equipment, and enhanced machine availability for better resource and maintenance utilization, has adversely affected their competitive advantage. The need to adopt a unique production technique that will curb their numerous equipment maintenance challenges, and also re-position them for world-class manufacturing will not only reduce their losses, but will also increase their throughput and profitability. To address a Pharmaceutical firm's maintenance challenges, data were obtained for the Overall Equipment Effectiveness (OEE) factors after Total Productive Maintenance (TPM) implementation in the company. Minitab 16.0 software was used to analyze the data collected, and the results showed that the highest value of 98.90 and 96.39 in the descriptive statistics for the maximum and mean respectively, underscore the importance of quality in the company's products. The percentage of mean for quality, availability, and performance obtained were 96.3906, 60.4938, and 27.6188 respectively. This once again showed that quality of products is the greatest OEE factor that pharmaceutical companies must take seriously in order to reduce the six big losses in their manufacturing processes. Response Surface Method (RSM), with the application of Design Expert software with Box-Behnken as the design type was used to model, analyze, and optimize the Overall Equipment Effectiveness (OEE) using availability, quality, and performance as the input parameters. The analysis of both the actual and coded values, which is the main contribution of the study showed that quality has the greatest value followed by availability and performance. Also, OEE must be set at 10.3 and 629.5 for both the lower and upper limits respectively, in order to effectively reduce downtime, setup cost, the inherent wastes, as well as the six big losses.

Keywords: Automotive engineering; Breakdown; Downtime; Equipment failure; Industrial engineering; Manufacturing engineering; Mechanical engineering; Overall equipment effectiveness; Performance; Quality; Six big losses; Total productive maintenance.

PubMed Disclaimer

Figures

Figure 1
Figure 1
A model of overall equipment effectiveness.
Figure 2
Figure 2
Illustration of sequence of tablet production in GPLL.
Figure 3
Figure 3
a: Main Effects plot for Availability; b: Main Effects plot for Quality; c: Main Effects plot for Performance.
Figure 4
Figure 4
a: Interaction plot for Availability and others; b: Interaction plot for Performance and others; c: Interaction plot for Quality and others.
Figure 5
Figure 5
Contour plot of performance vs Availability.
Figure 6
Figure 6
Contour plot of Quality vs Performance.
Figure. 7
Figure. 7
Response Surface plot of Performance vs Availability.
Figure 8
Figure 8
a: Desirability Contour plot of Quality vs Availability; b: Overall Equipment Effectiveness Contour plot of Quality vs Availability.
See this image and copyright information in PMC

References

    1. Adolph S., Kubler P., Metternich J., Abele E. Overall commissioning effectiveness: systematic identification of value-added shares in material supply. Proc. CIRP. 2016;41:562–567.
    1. Advice-Manufacturing Overall equipment effectiveness OEE and the six big losses. 2019. http://www.advice-manufacturing.com/Overall-Equipment-Effectiveness-OEE.... [Online]. Accessed on 5 January 2020, from.
    1. Dal B., Tugwell P., Greatbanks R. Overall equipment effectiveness as a measure for operational improvement: a practical analysis. Int. J. Oper. Prod. Manag. 2000;20(12)
    1. Ihueze C., Okpala C. The tools and techniques of lean production system of manufacturing. Int. J. Adv. Eng. Technol. 2014;V(Iv)
    1. Jain A., Bhatti R., Singh H. Proceedings of International Conference on Smart Technologies in Mechanical Engineering, Paper No. 17, Delhi Technological University, Delhi. 2013. Implementation of autonomous maintenance for the improvement of OEE of machines in SMEs – in context of Indian enterprises.

LinkOut - more resources