The Situation
The plant ran long shifts but still missed schedule. Presses were available, but unstable between jobs.
High-mix job switching, startup loss, and recurring stoppages were visible operationally but not measured at cause level.
Because only output was tracked, upstream losses stayed invisible and uncontested.
What We Did
We made losses visible first, then attacked the largest repeat drains with evidence-led routines.
- Implemented press- and shift-level OEE dashboards to move reviews from opinion to data.
- Filmed changeovers and applied SMED using observable facts instead of memory.
- Ran daily floor-level 5-Why reviews to convert recurring stops into closed corrective actions.
- Improved MTTR and MTBF discipline so breakdowns cost less and repeat less.
The Results
In twelve months, OEE improved 123%, changeover time reduced 47%, and wastage reduced 36.6%.
The team now owns daily problem solving with a measurement system that keeps the next loss visible.
Strategic Takeaway
- You cannot improve what you only measure at shift-end.
- On-time performance issues often begin in the first minutes of each job.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
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Bengaluru
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