Enhancement of Overall Equipment Effectiveness (OEE) through the use of Industry 4.0: In the case of Hilina Energy-Enriched Foods Manufacturing Industry
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Date
2023-06
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Addis Ababa University
Abstract
Overall equipment effectiveness (OEE) is a metric used to measure machinery effectiveness while
Industry 4.0 (I4.0) is a revolution of digital transformation which used to change convectional
manufacturing industry to smart manufacturing industry, through its evolution always open for
improvement of productivity, equipment effectiveness and efficiency of machinery, as well as
create comfort zone for human and other habitats. This study aims to identify equipment
effectiveness metrics and possible solutions for enhancing OEE in the manufacturing industry,
specifically in the case of the Hilina energy-enriched foods manufacturing industry. By utilizing
a mixed-methods explanatory research approach that involves qualitative and quantitative data
collection and analysis with the aid of advanced analytics techniques and recognize patterns
trained with data, big data is used. The data analysis identifies the biggest losses occurring at
auxiliary grand machines, especially the filler and packaging machines, resulting in a current
actual OEE of only 33.46 percent. However, the remaining auxiliary machines have an OEE of
79.64 percent, giving an overall OEE of 68.34 percent. Consequently, the study advocates using I
4.0 technologies such as the Internet of Things (IoT), smart devices with sensors, machine
learning, and vision to mitigate downtime, speed, and quality losses of auxiliary grand machines
and provide solutions to these issues. Moreover, through the analysis of big data, the study
provides maintenance strategies and machine setups that can help reduce unexpected failures, the
largest losses in organizations. Thus, the use of I 4.0 technologies can enhance OEE in the
manufacturing industry by providing possible solutions for each problem. It is noted that the OEE
improved from 68.34% to 73.36%. This study concludes that by using the industry 4.0 in the
organizations can effectively enhance the effectiveness of their equipment and achieve maximum
effectiveness.
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Keywords
Overall equipment effectiveness, Industry 4.0, Root cause analysis (RCA), Big-data, Six big losses