✅ Case Study | Productivity Improvement Based on OEE in a Foundry
At **ARAD Foundry Analysis**, we specialize in measurable productivity improvement for foundries. In this case study, we successfully optimized **Overall Equipment Effectiveness (OEE)** and operational performance at a full-scale metal casting plant.
🏭 Project Title:
**Comprehensive Efficiency Optimization Based on OEE in a Foundry**
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📌 Project Overview
This project aimed to identify inefficiencies and apply actionable solutions across the production line. Key focus areas included:
– Real-time OEE analysis and visualization
– Process stabilization in melting, molding, pouring, and cleaning
– Downtime reduction and performance monitoring
– Workforce training and SOP optimization
The project was carried out using **Tahlilgaran Zob’s proven consulting framework** for productivity enhancement.
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🧩 Approach & Methodology
Our team implemented a systematic, data-driven approach:
– 📊 Collected and analyzed production, downtime, and scrap data
– 🔍 Performed **root cause analysis** on bottlenecks in critical operations
– 🛠 Mapped losses across machines, processes, and human factors
– 📉 Used OEE tracking tools and developed visual **performance dashboards**
– ✅ Rolled out practical, **cost-effective solutions** for operational consistency
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🏆 Key Results
– 📈 **12% increase in OEE** within just 90 days
– ⏱ Reduced unplanned downtime by over 30%
– 🧑🏭 Enhanced operator efficiency with revised SOPs and on-site training
– 🔄 Established a **continuous improvement system** using lean tools
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💡 Why It Matters
This project illustrates how combining **industrial engineering**, **data analytics**, and **hands-on consulting** can result in significant cost savings, improved process stability, and long-term growth.
Looking to improve your foundry’s performance?
📩 [Contact us now](https://www.afacasting.com/contact) to learn how we can help you achieve measurable OEE gains.
