An organization has more than 1,000 machines which are continuously operating. Out of these machines, about 148 machines are bottleneck machines. Bottleneck is a process or a machine in a value stream which has the highest cycle time and decides the maximum technical capacity of the value stream/line, hence affecting the Overall Equipment Effectiveness (OEE). OEE is a worldwide established metric for the current process control of Total Productive Maintenance (TPM) activities, and it is a metric for the output of MAE during a selected period. Currently, to record the utilization of these machines, workers enter hourly production and losses of the unit on Hourly Monitoring Chart, and at the end of the day, the foreman sums up all these, enters them on an Excel sheet according to cell. Excel sheets are stored on the server that can be accessed by anyone in the organization. These Excel sheets are used to produce important charts like OEE with losses and Pareto chart, which are very essential to management heads to take decisions. For plant manager and department head to get the Pareto chart, they have to go about searching for relevant Excel file on the server. To look into the Pareto of whole plant or department, the Excel sheets need to be consolidated manually, which takes 3-4 days and causes delay in the preparation of Pareto. The aim of this paper is to streamline the whole process by an IT solution, which helps to reduce the delay in the preparation of charts and improve OEE of bottleneck machines at shop floor. Overall, the paper helps XYZ Production Systems—BPS with a system that will be reliable and at the same time more effective and less time-consuming, hence boosting OEE.

Currently, XYZ Company has more than 1,000 machines which are continuously operating round the clock. Out of these machines, about 148 machines are bottleneck machines. Bottleneck is a process or a machine in a value stream which has the highest cycle time and decides the maximum technical capacity of the value stream/line, hence affecting the Overall Equipment Effectiveness (OEE). OEE is a worldwide established metric for the current process control of Total Productive Maintenance (TPM) activities, and it is a metric for the output of MAE during a selected period.

To record the utilization of these machines, workers enter hourly production and losses of the unit on Hourly Monitoring Chart, and at the end of the day, the foreman sums up all these, enters them on an Excel sheet according to the cell. Excel sheets are stored on the server that can be accessed by anyone in the organization (James, 2001). These Excel sheets are used to produce important charts like OEE with losses and Pareto chart, which are very essential to management heads to take decisions (Keniche and Keisuke, 1998). For plant manager and department head to get the Pareto chart, they have to go about searching for the relevant Excel file on the server. To look into the Pareto of whole plant or department, the Excel sheets need to be consolidated manually, which takes 3-4 days and causes delay in the preparation of Pareto.

Mechanical Engineering Journal, OEE, Bottleneck, Database, Excel, TPM, Feed pump, SFMC, Junker machine, Dashboard, Analysis, Pareto.