Unraveling the Root Causes of Low Overall Equipment Effectiveness in the Kit Packing Department: A Define–Measure–Analyze–Improve–Control Approach

Low Overall Equipment Effectiveness (OEE) remains a critical challenge in manufacturing, affecting productivity and operational efficiency. This study investigates the persistent issue of low OEE in the kit packing department of a South African Original Equipment Manufacturer, where frequent downtime (DT) has resulted in OEE that is consistently below 60%. Using the Define–Measure–Analyze–Improve–Control (DMAIC) methodology, this research identifies the root causes of inefficiencies before implementing corrective actions. Data analysis revealed that material-related issues (84%) and manpower issues (15%) were the primary contributors to downtime. These inefficiencies led to equipment underutilization and financial losses due to production delays and overproduction of unnecessary kits. This study significantly enhances manufacturing efficiency by addressing these root causes, leading to reduced downtime and optimized machine usage. The financial benefits include substantial cost savings and improved resource utilization. The methodology and findings are applicable across various industries, contributing to the broader field of industrial engineering. The research highlights how misalignment between production planning and execution exacerbates inefficiencies. While this paper presents findings from the Define, Measure, and Analyze phases, the Improve and Control phases will follow in future work. The results provide a foundation for developing targeted interventions to enhance OEE and manufacturing performance.