S1E8: OEE Under the Microscope – How to Identify and Eliminate Losses

This episode puts Overall Equipment Effectiveness (OEE) under the microscope and shows how data-driven tools—from IoT sensors to full-blown digital twins—help uncover and eliminate hidden production losses. We explain what OEE really measures (Availability × Performance × Quality), walk through proven methods for capturing micro-stoppages in real time, and illustrate how simulation lets you test improvements before touching the line. You’ll also hear quick-win examples, a DBR77 case study that pushed OEE from 62 % to 75 % in just six months, and the most common mistakes that keep numbers stuck in the red. 

Without a focused OEE strategy, manufacturers typically struggle with:

• Frequent unplanned equipment downtimes—from breakdowns to material shortages—that steal valuable uptime. 
  
  
• Lengthy changeovers and setups that erode shift capacity and delay orders. 
  
  
• Slow cycle times or “creeping speed loss,” where machines run below their rated pace but the gap goes unnoticed. 
  
  
• Quality defects and scrap that inflate costs and mask deeper process issues. 
  
  
• Undocumented micro-stoppages—dozens of sub-minute interruptions that look harmless individually but add up to serious productivity leakage. 
  
  

Tune in to learn how to spot these losses fast, engage your team in continuous improvement, and turn OEE into a springboard for sustainable profit growth.

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