With consumer demands increasing and supply chains becoming more complex, FMCG manufacturers are under constant pressure to optimise their production lines and improve productivity.
One of the most effective ways to measure and improve operational performance is through Overall Equipment Effectiveness (OEE). This metric has become the gold standard for assessing manufacturing productivity, but achieving world-class OEE scores is no small feat.
What is OEE
And Why Does It Matter?
OEE is a comprehensive metric that evaluates the effectiveness of production equipment by measuring three key factors:
- Availability – How often the equipment is running as expected.
- Performance – How fast the equipment operates compared to its maximum capacity.
- Quality – The proportion of products produced without defects.
An ideal OEE score of 100% means the equipment is running at full capacity, producing zero defects, with no downtime.
However, most FMCG manufacturers fall short of this benchmark due to factors such as unplanned downtime, machine inefficiencies and production slowdowns.
How to Improve OEE
We’ve spent over 50 years helping Australia's manufacturers master the art of OEE improvement.
From single, well-selected machines that can transform a packaging line to complete packaging line integration, our expertise in OEE optimisation is helping FMCG manufacturers drive productivity, reduce downtime, and lower costs.
We take a holistic approach to improving OEE by offering solutions that optimise all three pillars of Availability, Performance, and Quality.
Here’s how our decades of expertise can help you achieve higher OEE scores:
Smart automation and predictive maintenance to improve OEE Availability
Availability refers to how often production equipment is available for use when it’s needed.
Downtime—whether planned or unplanned—can drastically affect an FMCG manufacturer's OEE score.
Foodmach tackles this challenge with:
- Advanced automation solutions: Our complete range of palletisers, depalletisers, conveying, fillers, labellers, stretch wrappers, coding and marking, inspection and traceability and software solutions are designed to reduce manual handling and minimise the risk of operator errors. By automating repetitive tasks, manufacturers can keep production lines running smoothly, reducing the amount of stoppage caused by human intervention. Even replacing or upgrading a single machine can make all the difference to your efficiency scores.
- Predictive maintenance technologies: Through Industry 4.0 levels of integration, Foodmach’s systems are equipped with real-time monitoring capabilities that predict and prevent potential equipment failures before they occur. With smart sensors and IoT-enabled devices, manufacturers can proactively schedule maintenance during off-peak hours, reducing unexpected downtime and increasing equipment availability.
- Quick changeovers: Our packaging lines are built to handle multiple SKUs and packaging formats with minimal downtime. This ensures that production lines remain available even when frequent product changeovers are required, making your operation more agile and responsive to market demands.
Intelligent, high-speed solutions to improve OEE Performance
Performance measures how efficiently equipment is operating compared to its theoretical maximum speed.
Underperforming machinery can be a significant drag on OEE scores.
Foodmach’s high-performance OEE solutions are designed to maximise throughput via:
- High-speed automation systems: Our equipment is engineered for speed without sacrificing accuracy. By operating at higher speeds, manufacturers can increase output and meet demand without requiring additional shifts or overtime.
- Customised line integration: Foodmach specialises in integrating new packaging technology into existing lines to ensure seamless operation from start to finish. This eliminates bottlenecks, reduces idle time, and keeps production lines running at maximum efficiency.
- Data-driven optimisation: Our automation solutions (including our software) uses real-time data analytics to monitor equipment performance. This allows manufacturers to fine-tune production speeds, identify inefficiencies, and continuously optimise line performance based on data insights.
Precision automation to improve OEE Quality
Quality is a measure of how many products are produced defect-free.
Even minor defects can lead to costly rework, waste, and delays, all of which can lower OEE scores. By minimising handling errors, manufacturers can reduce the risk of defects and improve overall product quality.
Foodmach’s automation systems are designed with quality control in mind, for example:
- Precision palletising and depalletising: Our robotic and conventional palletisers offer unmatched precision when handling products, ensuring that even delicate items are palletised or depalletised without damage.
- Stretchwrapping: Robopac's patented CUBE technology enables multi-level variable pre-stretch up to 400%, delivers optimal containment force at each level, allows strategic film placement and proactive corner compensation. The result is high-quality and stable wrapping that offers superior protection with up to 55% film savings.
- Filling: Mengibar's fillers adjusting the filling amount for every single fill, so wastage is greatly reduced. In contrast, competitor machines usually run a calibration cycle only once per shift. Menigbar machines typically deliver an accuracy of 0.15% sigma vs competitor machines which average 0.5% sigma.
- Labelling: P.E. Labellers offer immaculate label placement accuracy with built-in vision systems. So precise, in fact, that they were selected for Chandon's intricate new sparkling wine labels.
- Automated quality inspection: Foodmach offers packaging lines with integrated automated quality checks throughout the packaging and palletising process. With machine vision systems and smart sensors, manufacturers can detect defects in real-time and prevent faulty products from moving further down the line.
- Coding and Labelling: Markem-Imaje's reliable, high-speed printers and labellers reduce unplanned stops and minimise downtime. They increase OEE Quality by minimising the risk of product rejection due to poor labelling. High levels of integration with factory systems enhance OEE Availability, ensuring real-time data monitoring, enabling quicker identification of inefficiencies and facilitating proactive maintenance.
Long-term OEE gains through continuous improvement
Achieving a high OEE score isn’t a one-time effort; it requires ongoing monitoring and continuous improvement.
Foodmach works closely with FMCG manufacturers to:
- Develop tailored solutions: We understand that every production environment is different. That’s why we work alongside manufacturers to assess their unique OEE challenges and design solutions that directly address bottlenecks, inefficiencies, and quality issues.
- Train operators and technicians: Foodmach doesn’t just deliver machines—we empower your workforce. Our comprehensive training programs ensure that operators and technicians know how to use automation systems to their fullest potential, helping to maintain high OEE scores long after installation.
- Ongoing support and upgrades: We're committed to helping manufacturers stay at the forefront of technology. We offer ongoing service, support, and system upgrades to ensure that our automation solutions evolve with your business. For instance, we're currently offering end-of-life robot replacement packages to our existing palletiser customers. Some of those palletisers are more than 10-15 years old and still working perfectly, just in need of a new robot arm with a Robowizard pallet pattern programming upgrade.
We drive world-class OEE with automation
For over 50 years, Foodmach has been helping FMCG manufacturers achieve world-class OEE scores through smart automation, seamless line integration, and a relentless focus on performance optimisation.
Whether you’re looking to reduce downtime, boost throughput, or enhance product quality, we have the expertise and technology to deliver tangible improvements to your production line.
As consumer demands grow, so do the pressures on FMCG manufacturers to produce faster, more efficiently, and with fewer resources. Let our automation solutions and OEE expertise be your competitive advantage.
