Eradicating Rework: How Smart Diagnostics Raised OEE to 78%
If your shop floor is battling a low First Pass Yield (FPY) or high manual rework rates, you’re not alone. Many UK manufacturers struggle with component defects, manual errors, and extended repair downtimes that severely impact overall profitability. A UK manufacturer processing precision components came to us with an OEE below 55% and an average repair downtime (MTTR) of 45 minutes per incident.
To fix these underlying issues, we integrated our automated profile cutting system with advanced, smart process automation diagnostics. The real data recorded after the installation demonstrates an incredible turnaround:
- OEE Surge: Overall Equipment Effectiveness surged from a failing 55% up to an impressive 78% within just three months.
- Near-Zero Rework: Defect rates and manual rework dropped to near-zero due to integrated Poka-Yoke error-proofing.
- Automated Verification: The smart cutting machine automatically verifies clamping, profile lengths, and material orientations before a single cut is made.
- Downtime Mitigation: Standardising automated checks removed the typical 45-minute MTTR delays that previously derailed shifts.
Investing in intelligent error-proofing ensures that your manufacturing process remains right the first time. By upgrading your shop floor with automated diagnostics, you remove human error, save valuable raw materials, and secure predictable product quality day after day.
WHO WE SERVE
We partner with forward-thinking manufacturers across:
- Metal & Sheet Fabrication
- HVAC & Building Systems
- Window Manufacturing
- Automotive Components
- Aluminium Extrusion
- Food & Pharma Processing
