Pharma
1.5% OEE improvement
.avif)
Background
The client was experiencing unidentifiable issues on a production line which manufactures more than 200 products per minute. These issues resulted in downtime every 15 minutes and significant Overall Equipment Effectiveness (OEE) losses.
Challenge
The speed and randomness of the issue made it difficult for operators to monitor and identify the root cause.
- With over 200 products manufactured per minute, issues occurred too rapidly for manual observation
- Irregular patterns made it challenging to anticipate when problems would occur
- The speed of production prevented operators from effectively monitoring failure events in real time
- The underlying factors driving downtime were unclear, leading to frequent production interruptions
Solution
PurpleSector’s Formula 1™-derived automated vision system was programmed to trigger on detecting non-normal events. These cameras captured 4,000 failures in the first 24 hours.
PurpleSector then trained a machine learning algorithm to analyse correlations between line parameters and failure modes. Using digital twinning, the team replicated the production line’s behaviour to identify the most efficient and effective solution.
.avif)
Results
Supply variation and equipment synchronisation were identified as the root causes of the issue.
Solutions were embedded to correct and prevent further issues leading to 1.5% reduction in OEE losses. The project delivered an ROI of 7:1.
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We deploy F1™ - derived tools, technologies and techniques to help organisations operate like an F1™ team. Our goal is to build the in-house capability for clients to solve challenges, uncover opportunities and deliver performance gains at race-pace.
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