Enhancing Manufacturing Efficiency by Improving Overall Equipment Effectiveness

Abstract

Cairo Pac, Egypt’s leading manufacturer of food cans, has maintained over 10 years of market leadership since its establishment in 2010. The company operates under ASAT for Trading & Industry, a holding company with over 25 years of experience in the production of food cans, beverage packing materials, three-piece cans, easy-open ends, and twist-off caps. Cairo Pac specializes in manufacturing three types of food cans. An investigation of the manufacturing line revealed low productivity caused by several factors, including losses in setup time and adjustment, idling and minor stoppages, equipment failures, reduced speed, process defects, reduced yield, and poor maintenance practices. The primary objective of this project is to enhance the Overall Equipment Effectiveness (OEE) by 17% and improve production efficiency by approximately 5.68%, the implementation of corrective actions has resulted in significant improvements. Machine performance and failure tracking have led to a time-saving of over 25%, equivalent to 63 minutes saved during each maintenance cycle across all machines in the factory. The reduction in idling and minor stoppages has contributed to substantial Furthermore, rework and scrap have been reduced by approximately 170,000 cans over two months, with productivity increasing from 88% to 93%. Engaging operators in daily maintenance routines and reducing rework have been key factors in achieving these improvements. This has been accomplished through the implementation of various methodologies, such as Total Productive Maintenance (TPM), reducing the six big losses, and utilizing parameter sheets. Additionally, the setup time has been reduced by approximately 45.45%, further enhancing overall operational efficiency.