Contents
1What OEE means and why it matters
Overall Equipment Effectiveness (OEE) Is the composite index of machine utilization, calculated as:
Compare OEE against the machine own baseline with identical data definitions. Never substitute generic benchmarks for real process context.
How much purge-time or reject cuts move OEE depends on that loss share of Planned Production Time and actually saleable capacity
2How ASACLEAN hits all 3 OEE parts
| Component | Related loss | Data to measure |
|---|---|---|
| Availability | Downtime from purging, screw pulls and post-stop startups | Minutes from last good part to first good part |
| Performance | Cycle time or output not back to standard | Ramp-up time and sub-standard-rate rounds |
| Quality | Rejects from Black Specks, color streaks and contamination | Reject counts and weights under identical gates |
3Availability: cut downtime
Injection purging-related downtime covers:
- Color and material changes
- Stops pulling nozzles, check rings or screws for cleaning
- Process re-tuning until parts pass gates
- Post-stop startup loss
Log each type separately before trials. Purging methods never help every cause equally. See residue prevention at Routine Purging article & Sealing
4Performance: cut setup loss
After color and material change, machines run below optimal a while until stable, called Ramp-up Loss — ASACLEAN completes material changes faster so operators set normal-cycle processes sooner.
5Quality: cut reject rate
Contamination rejects must split from other causes (parameters, mold, dryer, material) to avoid overstating purging. Fix defect codes and check methods identically across baseline and trial.
6Workable ROI formulas
Base formula plant managers use:
Monthly calc:
- Count monthly color and material changes (such as 20)
- Find current baseline: avg discarded-resin kg per time, time per time, rejects per lot
- Run Controlled Trial with real measured values under identical gates
- Multiply by costs into baht
- Subtract monthly ASACLEAN spend
- Result = monthly Net Saving Payback Period = initial investment divided by Net Saving per period
Or run the on-web calculator at ROI calc page
7Data form for calculation
Use this table for same-machine, same-change-type, comparable-window data:
| Item | Baseline | Controlled Trial | Unit and evidence |
|---|---|---|---|
| Material used purge-start to pass | Enter real values | Enter real values | Kg from weigh and issue slips |
| Time from last good part to first good part | Enter real values | Enter real values | Minutes from machine log |
| Scrap or rework | Enter real values | Enter real values | Kg or counts with defect code |
| Purging plus extra costs | Enter real values | Enter real values | Baht per time |
| Monthly counts | Counts of similar-term jobs | Times per month | |
Figures should pass joint review across Production, Quality, Maintenance and Finance before scale-up decisions
Calculate your plant ROI
Enter real figures, answers in seconds with executive-ready Report
8Presenting to executives
Presentation patterns easing assumption checks and decisions:
- Start from executive pain: Reject lots, customer complaints, insufficient capacity
- Use real baseline figures: Never standards. Pull from MES or shift logs.
- Pre-define the pilot: 1 machine and recurring jobs, trial rounds per process volatility
- Calculate conservatively: Only time returning to genuinely demanded production, plus all method-switch costs
- Show a scale-up plan: Post-pilot to every machine. Annual Saving.
9FAQ
By what percent does ASACLEAN raise OEE?
No constant fits every plant. Measure Availability, Performance and Quality before and after Controlled Trials in identical windows and gates. Results vary by machine, resin, color-change jobs and reject causes.
How many months to ASACLEAN payback?
Payback hinges on color and material change counts, resin amounts, machine time, reject costs and new-method spend. Use baseline data with real trial results. Never another plant average as the guarantee.
What is OEE?
OEE (Overall Equipment Effectiveness) = Availability x Performance x Quality, tracking whether losses come from run time, production speed or quality, with consistent data definitions
No MES. How to start logging?
Start from forms logging start-end times, material weights, reject counts and each job terms. Consistent logging computes OEE and ROI without waiting for automation.
Key references
ROI and OEE figures in this article illustrate thinking methods. Real outcomes depend on each plant machines, materials, processes and costs.