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Reducing OEE Losses Through Autonomous Maintenance Step 1 Implementation on a Bottling Line

A tequila bottling facility sought to reduce overfill waste after several unsuccessful improvement attempts. The organization faced a widespread belief that the issue was too complex to solve and that existing equipment lacked the capability to achieve meaningful reductions.

Industry: Food & Beverage

Service: Manufacturing

Service: Operational Excellence

Service: Operations Due Diligence

Service: People and Organization

Parallaxe

Our Client

A leading beverage manufacturer was experiencing recurring performance losses on a critical bottling line. The case packer was selected as the pilot machine due to its deteriorated condition and frequent stoppages, which negatively impacted overall line performance.

Parallaxe

The Challenge

  • Frequent minor stops affecting overall equipment effectiveness (OEE)
  • Deteriorated machine conditions causing recurring performance losses
  • Limited operator familiarity with the equipment
  • Difficulty sustaining previous improvement efforts
  • Need to establish stronger operator ownership and equipment care practices

Real Results Achieved Together

Previous improvement initiatives had generated temporary gains, but results were not sustained. In addition, a large percentage of operators were relatively new to the equipment, limiting operational knowledge and ownership.

EFESO implemented Autonomous Maintenance (AM) Step 1 as part of a TPM deployment focused on restoring and maintaining basic equipment conditions.

  • Minor stops reduced from 9.4% to 3.7% (61% reduction)
  • Operational adjustment losses reduced from 6.5% to 5.0% (23% reduction)
  • Improved equipment stability and reliability
  • Increased operator ownership and equipment knowledge
  • Enhanced teamwork and accountability across functions

61%

Reduction in minor stops

23%

Reduction in operational adjustment losses

Transformation Impact

  • Strong engagement from operators, line leaders, and maintenance teams
  • Consistent execution of Autonomous Maintenance routines
  • Daily auditing and coaching to reinforce behaviors
  • Clear accountability and sustained abnormality management
  • Cross-functional collaboration between Operations, Maintenance, and Continuous Improvement
Parallaxe

Our Approach

Key activities included:

  • Conducting comprehensive cleaning and inspection exercises to identify abnormalities
  • Repairing equipment defects identified during machine restoration activities
  • Engaging operators, line leaders, and maintenance personnel in daily equipment care
  • Establishing a continuous tagging process to identify and address abnormalities
  • Developing and refining Cleaning, Inspection, Lubrication, and Tightening (CILT) standards with operator involvement
  • Performing daily audits and coaching to reinforce Autonomous Maintenance practices
  • Strengthening collaboration between Operations, Maintenance, and Continuous Improvement teams

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Facing Similar OEE Production Challenges?

  • Implement cross-functional collaboration between Operations, Maintenance, and Continuous Improvement
  • Increase operator ownership and equipment knowledge and enhance teamwork and accountability across functions
  • Create clear accountability and sustained abnormality management
Contact our experts

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