OEE and maintenance strategy development for a global beverage manufacturer — structured around the highest-impact production line failure modes identified through loss analysis and RCA.
The manufacturer was experiencing recurring production losses on its highest-volume lines without a structured process to identify and eliminate the root causes. Maintenance was primarily reactive, and OEE measurement was inconsistent across shifts — making it difficult to distinguish systemic issues from one-off events.
Optimal implemented consistent OEE measurement across the production lines and conducted a structured loss analysis to identify the highest-impact failure modes. RCA was applied to the top loss contributors, and a targeted maintenance strategy was developed to address the identified failure causes — moving from reactive response to proactive management of the critical failure modes.
The manufacturer achieved sustained OEE improvement on the highest-volume production lines. The structured approach to loss analysis and RCA gave the maintenance and operations teams a repeatable process for identifying and eliminating production losses.