Improve OEE with an Industrial Smartwatch: Enhancing Performance and Quality

Main Value Proposition

The Workerbase Connected Worker Platform in combination with an industrial smartwatch offers a transformative solution for improving Overall Equipment Effectiveness (OEE). By reducing machine downtimes, speeding up changeover processes, and providing real-time alerts to the right personnel, Connected Worker technology empowers operators to make faster decisions and resolve issues on the go. With OEE being the gold standard of manufacturing productivity, the smartwatch helps ensure that availability, performance, and quality are optimized. This leads to fewer disruptions, higher throughput, and more efficient use of resources.

The Challenge

Machine downtime—whether planned or unplanned—has a significant impact on production rates and profitability. Unplanned downtime, often caused by technical failures, poor processes, or operator errors, leads to unpredictable costs and resource utilization. Planned downtime, while necessary for activities like maintenance or machine setup, also reduces overall productivity:

• Unplanned Downtime: This is particularly costly because it occurs unexpectedly, often due to equipment failures, material shortages, or human error. Since it cannot be planned or calculated, it disrupts production schedules and requires immediate, unplanned interventions.
• Planned Downtime: Activities like maintenance, cleaning, or machine changeovers are scheduled, but they still take time away from production. Minimizing planned downtime can dramatically improve OEE.

Solution Principle

The Workerbase platform helps manufacturers tackle both unplanned and planned downtime. It integrates with machines to provide real-time alerts and instructions directly to workers’ wrists. This allows them to respond faster to machine issues, reducing downtime and boosting productivity. For planned activities like changeovers, the smartwatch ensures operators have the right tools and instructions available instantly, streamlining the process. Find out more about how this solution package is being actively used by GKN to transform their operations in our case study here.

Solution in Detail

• Real-Time Machine Alerts: In multi-machine environments, one of the main challenges is notifying operators about issues as soon as they arise. Workerbase’s Connected Worker platform delivers machine alarms in real-time to the operators who are qualified to resolve the issue. This reduces the time lost between problem identification and resolution. If additional support is needed, operators can quickly escalate issues or request assistance through the app, ensuring the fastest possible response time.

• Streamlining Machine Changeovers: Workerbase provides dynamic work coordination for machine changeovers, ensuring the right personnel and tools are available to minimize downtime. Operators can retrieve work instructions via a simple QR code scan, while the system logs all workflow data for continuous improvement. By reducing setup times through precise, mobile-enabled instructions, manufacturers can increase the number of units produced each day.

Core KPI: Overall Equipment Effectiveness (OEE)

OEE measures manufacturing productivity by combining three critical factors: Availability, Performance, and Quality. Each factor can be improved through better machine uptime, real-time data, and mobile task management:

• Availability: Reducing both planned and unplanned downtimes boosts machine availability. Workerbase’s smartwatch ensures that operators can respond to machine failures immediately, minimizing downtime.

• Performance: Slowdowns in production often stem from machine jams, material issues, or underutilization of equipment. Workerbase’s smartwatch addresses these performance losses by providing operators with real-time data and alerts. For example, if a machine slows down due to suboptimal material quality, the smartwatch immediately notifies the operator, who can then check the status, troubleshoot, and resolve the issue swiftly. Additionally, Workerbase can track machine speed and notify operators when the production line is running below capacity, ensuring prompt corrective action to maintain optimal performance.

• Quality: Ensuring that only parts that meet standards are produced is key to achieving high OEE. Workerbase helps tackle quality issues by equipping operators with mobile checklists and digital work instructions that allow them to easily note and address issues as they arise. For example, when a defect is detected, the operator can record the issue directly into the system using the smartwatch, ensuring that quality control measures are taken immediately. This prevents faulty parts from moving down the production line and allows for efficient rework when necessary, ultimately reducing scrap and maintaining high production standards.

Summary

Integrating the Workerbase Connected Worker platform in combination with the Workerbase industrial smartwatch into your manufacturing process is a game-changer for improving OEE. By minimizing machine downtime, streamlining changeovers, and empowering workers with real-time data and alerts, manufacturers can operate at peak efficiency. This wearable solution not only improves Availability, Performance, and Quality but also drives continuous improvement by providing actionable insights from machine and worker performance.

By connecting workers to critical processes and machines, Workerbase helps you keep operations running smoothly and at maximum efficiency, leading to significant improvements in OEE and overall productivity.