Improving Machine Effectiveness Using the Overall Equipment Effectiveness (OEE) Method and Lean Manufacturing in the Automotive Components Industry

Abstract

Low machine effectiveness can reduce production efficiency through equipment failures, lengthy setup activities, speed losses, and product defects. Previous studies have generally examined machine effectiveness and lean manufacturing separately, leaving limited discussion of their integrated use to identify operational losses and formulate measurable process improvements. This study aims to evaluate machine effectiveness and identify production waste in an automotive manufacturing process to develop improvement strategies. A descriptive quantitative approach was employed using production, operating time, downtime, and defect data collected from January to December 2025. Machine effectiveness was evaluated based on availability, performance, and quality, while lean manufacturing analysis used value stream mapping, process activity mapping, seven wastes, and six major loss categories, supported by Pareto and cause-and-effect analyses. The results showed average availability of 67.39%, performance of 74.16%, quality of 73.42%, and overall effectiveness of 36.56%. Equipment failure was the largest loss at 38.26%, followed by setup and adjustment at 21.39%. The proposed improvements include preventive maintenance, autonomous maintenance, setup time reduction, standardized procedures, operator training, and improved material flow. The novelty lies in integrating machine effectiveness measurement with lean waste analysis to develop a future production state with projected effectiveness of 92.28%.