Improving OEE

From theory to practice: Continuous improvement with a data-driven focus

To sustainably increase productivity in manufacturing, you need more than just the right KPIs—you need a structured approach. We recommend combining continuous improvement with data-driven root cause analysis.

To accomplish this, we integrate two proven concepts: the PDCA cycle and the Biggest Loss Analysis based on the 6 Big Losses framework.

What is the PDCA Cycle?

The PDCA cycle is a tool for continuous improvement. It consists of four sequential phases:

1

Plan

A specific problem or improvement opportunity is identified, and a plan is created. This includes setting goals, allocating resources, creating schedules, and developing strategies.

2

Do

The plan is implemented. It is important to closely monitor the execution to ensure it follows the defined guidelines.

3

Check

The results are compared with the original objectives. This includes collecting data and identifying deviations. The check phase aims to determine whether the implemented actions were successful and if further adjustments or improvements are needed.

4

Adjust (formerly Act)

Based on the results, actions are taken to optimize the process. This may involve adjusting the plan, identifying new solutions, or improving existing workflows. For this reason, we use the term "Adjust" instead of "Act".

Combining the PDCA Cycle with the 6 Big Losses

By combining the PDCA cycle with an analysis of the 6 Big Losses, a powerful tool for continuous efficiency improvement is created.

• Focus on the biggest levers: The structured breakdown into loss categories allows targeted action in the areas with the greatest improvement potential.

• Sustainable improvement: Repeated application of the PDCA cycle helps embed improvements into the process—leading to long-term increases in OEE.