Up to 123%
OEE Improvement
More effective capacity from the same machines.
OEE & Equipment Performance Improvement Consulting
Most equipment losses do not stem from major breakdowns, but from recurring inefficiencies that become part of daily operations. Over time, these hidden losses significantly erode actual production capacity. Before investing in new assets, we help you identify and unlock the capacity already embedded within your existing systems.
India | Middle East | Africa
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Results Section
What You Gain
Up to 63%
Changeover Time Reduction
Faster setups mean more available run time.
Up to 40%
Downtime Reduction
Fewer breakdowns and stoppages eating your hours.
Up to 37%
Wastage & Quality Loss Reduction
Fewer rejects, less rework, cleaner first-pass output.
Up to 58%
Output Improvement
Higher throughput from equipment you already own.
Up to 28%
Productivity Improvement
More out of every operator and every machine.
Pain Point Section
Is Your Equipment Losing Performance Without You Realising It?
Equipment operating below rated capacity
Machines deliver less than their true potential due to unmeasured performance gaps.
Frequent breakdowns and unplanned stoppages
Unexpected interruptions reduce available production time and disrupt flow.
Long and inconsistent changeovers
Setup times consume capacity and vary across shifts, operators, and products.
Untracked minor stoppages
Small interruptions accumulate into significant productivity losses.
Recurring defects and rework
Quality issues increase cost while reducing effective output.
Reactive maintenance approach
Teams focus on fixing failures instead of preventing them.
Limited visibility of equipment losses
Availability, speed, and quality losses are not clearly measured or managed.
Decisions driven by assumptions
Lack of reliable data leads to repeated operational inefficiencies.
Solution Section
Where We Help You Succeed
OEE measurement & loss visibility
Establish true OEE and break it down into the six big losses to make issues measurable.
Availability improvement
Reduce breakdowns and unplanned stoppages to recover lost production time.
Changeover reduction (SMED)
Convert internal to external setups and standardise processes to cut changeover time.
Performance improvement
Eliminate minor stoppages and speed losses that quietly reduce output.
Quality loss reduction
Minimise defects and rework to ensure right-first-time production.
TPM implementation
Build preventive and autonomous maintenance into daily operations.
MTBF & MTTR improvement
Increase time between failures and reduce recovery time.
OEE dashboards & review systems
Create real-time visibility and structured reviews to drive data-based decisions.
Live Production Intelligence & Loss Monitoring
Monitor Real-Time Machine Performance
Track machine performance, downtime reasons and production losses in real time. Give your teams the transparency they need to improve performance, increase accountability and maintain results.
See How It WorksOEE
54%
▲ from 38% in 3 months
Availability
75.5%
+14.9%
Downtime
−449m
per month
Output
1,923
+519 units
Our Approach
The Gemba Approach
A proven 5‑phase methodology delivered on your shop floor — not from a boardroom. Every phase is hands‑on, data‑backed, and measured against a signed baseline.
Assessment & diagnostics
A 2-4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.
Scope, deployment & commercials
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
Current state mapping & baseline
Every process mapped in detail. A signed performance baseline established - the reference point against which every improvement is measured.
Proof of concept, implementation & on-site training
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba in real conditions, under real pressure.
Sustenance & audit handover
Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.
We don't exit on a deadline. We exit when the results hold.
Every engagement includes audit handover and built‑in review systems.
Case Studies Section
Featured Case Study
Real project outcomes across equipment-intensive manufacturing, with measurable OEE gains and sustained improvements.
Printing & Packaging
123% OEE Improvement
A national packaging and label printing leader serving the AlcoBev, food, and pharma sectors more than doubled its OEE over a 12-month engagement.
123% OEE improvement47% changeover reduction36.6% wastage reduction
Key Levers
- Changeover videography & SMED
- Daily 5-Why reviews
- MTTR & MTBF improvement
- Purpose-built OEE dashboard
Solar Manufacturing
Stringer OEE Raised from 38% to 54%
At a ₹2,500+ crore solar PV facility, stringer OEE rose from 38.4% to 53.7% in three months. Downtime reduction, TPM routines, and standardised rework eliminated approximately 449 minutes of stoppage per month.
OEE 38.4% → 53.7%Availability 60.6% → 75.5%449 min/month stoppage eliminated
Key Levers
- Downtime reduction
- TPM routines
- Standardised rework
- Daily output 1,404 → 1,923
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything manufacturers usually ask before starting an OEE & Equipment Performance engagement.
What is OEE?
OEE measures how much of your planned production time is truly productive. It combines availability, performance, and quality to show the gap between actual and potential output.
What is a realistic OEE benchmark?
Most manufacturers operate at 40–60% without visibility. Best-in-class is ~85%, but the priority is measuring your current reality accurately.
How much improvement is possible?
Typical structured improvements deliver 20–40% gains. Higher gains are common where losses were not previously measured.
What causes low OEE?
The six big losses: breakdowns, setup time, minor stoppages, speed loss, defects, and startup rejects. Performance losses are often the most underestimated.
Do you implement on-site?
Yes. We work on the shopfloor through measurement, implementation, and stabilisation, until results are sustained.
Which industries benefit?
Any equipment-driven operation — solar, packaging, cables, chemicals, pharma, metals, and both process and discrete manufacturing.