Machine Performance Variance
Four identical machines achieved different OEE (76-94%) for identical work. Variance was attributed to 'normal variation,' but the 18-point spread suggested systematic differences.
What Became Visible
Machine-level benchmarking analysis revealed: highest-performing machine (94% OEE) had more experienced operator, tighter changeover procedures, and more frequent preventive maintenance. Lowest-performing machine (76% OEE) had newer operator, longer changeovers, and reactive maintenance. The difference was methodology, not machinery.
Best-Machine Standardization
Highest-performing machine's operational approach documented and standardized across all machines. Operator training, changeover procedure, and maintenance discipline aligned facility-wide.
How it worked: Identified best-performing machine and its operational practices. Systematic replication of these practices across other machines.
Results
machines now aligned
from equipment standardization
Identical equipment with different results indicates methodology differences. Best-machine practices when systematized bring all machines toward high-performer level.
Operational Reality
Three machines were underperforming due to different operational approaches. Standardizing best practices improved facility baseline significantly.