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Case study 3: +8% OEE, +9% Production, +₹0.7 Crore/Day Revenue: The Power of Real-Time Efficiency

Through real-time monitoring, smarter planning, and operator training, EroNkan helped a leading manufacturer achieve higher equipment availability, better performance, and a 9.27% production increase.

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Introduction

OEE data analysis conducted across multiple production cycles by Eronkan
team.
Collaborated with client’s operations team to deliver targeted recommendations.
Client implemented real-time monitoring to optimize efficiency.
Improved production planning to maximize availability and resource use.
Reduced downtime through refined planning processes.
Operators trained to run machines at standard speeds for consistency.

Observations

Data analyzed for one week.
Most lines showed performance <85%, some even <70%.
Machine-level analysis showed high no combination counts due to:
- 1–3 hoppers disabled by operators.
- Tight target weight range for higher-value products.
- Uneven product distribution caused by low product drop and improper
  feeder vibration settings.
Improvement potential: >32 tons/day packing capacity across 7 lines.

Improvement in Overall Equipment Efficiency

Baseline (17–19 May):

After Improvements (28–30 May):

Significant improvements achieved in both availability and performance,
resulting in a strong OEE gain.

OEE Baseline & Improvement Data

Improvement In Production

The improvements in Overall Equipment Efficiency (OEE) directly translated into

higher production output. Comparing baseline and improvement periods shows a

clear positive correlation:

OEE Improvement: +8.09% (from 64.29% 72.38%)

Production Output Increase: +9.27%

This demonstrates that operational corrections, maintenance efforts, and proper

training not only enhanced equipment efficiency but also delivered tangible gains

in production.

The improvements in Overall Equipment Efficiency (OEE) directly translated into

higher production output. Comparing baseline and improvement periods shows a

clear positive correlation:

OEE Improvement: +8.09% (from 64.29% 72.38%)

Production Output Increase: +9.27%

This demonstrates that operational corrections, maintenance efforts, and proper

training not only enhanced equipment efficiency but also delivered tangible gains

in production.

The improvements in Overall Equipment Efficiency (OEE) directly translated into

higher production output. Comparing baseline and improvement periods shows a

clear positive correlation:

OEE Improvement: +8.09% (from 64.29% 72.38%)

Production Output Increase: +9.27%

This demonstrates that operational corrections, maintenance efforts, and proper

training not only enhanced equipment efficiency but also delivered tangible gains

in production.

Observations

An 8.09% improvement in OEE directly translated into higher production output.

The rise in production figures highlights the positive impact of equipment

efficiency on overall performance, validating the strong correlation between

improved OEE and increased productivity for the organisation.

Overall Improvement

By improving Performance (+3.04%), Availability (+6.15%), and OEE (+8.09%), the

overall average production increased by 9.27%, translating to a daily output boost

of 33.24 tons. These improvements directly enhanced operational efficiency and

productivity, driving a significant increase in overall production output.

Highest Production 11th May

Availability: 81.33% | Performance: 91.54%

OEE: 74.45% | Production Output: 430.52 tons

Clear correlation observed — higher OEE directly boosted production
performance.
Insights empower the client to focus on OEE optimisation for sustained
productivity and operational success.