Maximizing OEE by Reducing Variability in a Capital-Intensive Operation

The Challenge

A global B2B manufacturer operating in a high-demand, capital-intensive environment struggled within consistent performance in equipment utilization. Variability in operational execution led to suboptimal productivity and unreliable throughput.

The mission: Increase Overall Equipment Effectiveness (OEE) by standardizing processes and eliminating variability.

Our Strategic Approach

Over the course of 18 months, Falconi deployed a six-phase strategy to steadily raise OEE from 68%to 95%, a 27 percentage point gain:

1. Governance and Discipline

• Introduced real-time analytics dashboards and planning support tools.
• Reinforced execution discipline to align operational focus.

2. Quick Wins

• Deployed predictive maintenance based on analytics.
• Identified low-effort, high-impact actions that generated immediate value.

3. Reduction of Variability

• Established interactive platforms and team enablement strategies to standardize     operational routines.
• Fostered a culture of predictability and stability.

4. Structural Gains

• Used IoT and AI-driven data to uncover hidden inefficiencies.
• Integrated Falconi’s startup ecosystem and advanced analytics to embed robust process controls.

5. Treatment of Deviations

• Created advanced systems to monitor, detect, and recover from deviations in     KPIs.
• Applied neural networks and fuzzy logic to manage complex production     environments.

6. Sustainability of Results

• Maintained high performance through:
   
  • Geolocation-enabled apps
   
  • Real-time KPI tracking
   
  • Employee enablement platforms

Results

Metric      Baseline       New Default

OEE             68%                 95%

Improvement : +27 percentage points

• Marked reduction in variability across key operational metrics.
• Performance gains sustained consistently over 18 months.
• Improved team ownership, visibility, and discipline.

People-Focused Gains

• Urgency creation encouraged faster adoption.
• Discipline and ownership were reinforced through visibility and results.
• A renewed sense of belonging and accountability improved talent retention and engagement.

📘 Conclusion

By combining real-time analytics, structured governance, and people-centered enablement, Falconi helped this manufacturer drastically improve its operational reliability. The sustained 27-point increase in OEE showcases the power of disciplined execution and smart technology adoption in driving long-term industrial efficiency.

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