Beyond the World Class Standards: A Case Study of Boosting OEE From 85.2% to 93.4%

The Importance of Maximizing OEE in the Starch Processing Industry 

Overall Equipment Effectiveness (OEE) is a crucial metric for manufacturers seeking to optimize production efficiency and maximize asset utilization.  

One of our clients in the Maize processing industries monitors their production productivity very closely. As they deal with multiple high-value products—such as starch powder, liquid glucose, dextrose monohydrate, maltodextrin, and dextrose syrup—are derived from the same raw material, any bottleneck in production can significantly impact overall output and profitability. 

For starch manufacturers, achieving world-class OEE levels means minimizing downtime, reducing process inefficiencies, and ensuring that critical equipment operates at peak performance. However, many plants struggle with persistent availability losses, unplanned downtime, and inefficient workflows that limit their ability to scale production effectively. 

This article explores a real-world case study of how KAIZEN™ methodologies and a structured problem-solving approach successfully increased OEE from 85.2% to 93.4% in a starch plant—unlocking higher maize processing volumes and boosting overall productivity. 

Identifying the Bottleneck: The Starch Plant’s Availability Challenges 

One of the most common barriers to improving OEE is availability losses—unplanned downtime, equipment failures, and operational inefficiencies that reduce productive time. In this case study, a leading starch processing plant faced limitations in its maize processing capacity due to constraints within its starch plant. This bottleneck directly impacted the output of all downstream products, including liquid glucose and dextrose syrups. 

An in-depth loss analysis conducted over a six-month period (January–June) revealed that availability issues were the primary driver of OEE losses, accounting for 80% of total downtime. The key culprits behind these losses included: 

• Extended Centrifuge Cloth Wash Time – Leading to excessive cycle time and production delays. 

• Power Outages – Causing unplanned downtime and production stoppages. 

• Equipment Breakdowns – Particularly in critical systems such as the Root Blower and Sling Fan Blower. 

• Frequent Sling Fan Tripping – Occurring at every startup, leading to additional downtime.

Implementing a KAIZEN™-Led Solution: Structured Problem-Solving for OEE Improvement 

To address these availability challenges and unlock greater OEE, the plant deployed a structured problem-solving approach based on KAIZEN™ and Lean Six Sigma methodologies. This initiative focused on a combination of cycle time reduction, equipment reliability enhancement, and operator re-training to drive sustained improvements. 

1. Reducing Centrifuge Cloth Wash Time Through Process Optimization 

• Conducted a detailed time study to map the entire centrifuge cloth washing process. 

• Identified and eliminated non-value-adding activities (Muda) that were prolonging the cycle. 

• Implemented a streamlined standard operating procedure (SOP), reducing wash cycle time by 27%, which directly increased machine availability and throughput. 

2. Minimizing Power-Related Downtime with PMS Optimization 

• Diagnosed inefficiencies in the Plant Power Management System (PMS) that were contributing to frequent outages. 

• Reset power distribution “rules” within the PMS to improve load balancing and system resilience. 

• As a result, power-related availability losses were significantly reduced, improving operational stability. 

3. Preventing Critical Equipment Failures with Proactive Maintenance 

• Conducted a complete mechanical overhaul of high-risk equipment: Root Blower and Sling Fan Blower. 

• Transitioned from reactive maintenance to a combination of Time-Based Maintenance (TBM) and Condition-Based Maintenance (CBM) for these critical assets. 

• Introduced predictive maintenance measures, preventing unplanned breakdowns and ensuring long-term equipment reliability. 

4. Eliminating Sling Fan Tripping with Operator Training 

• Identified incorrect startup procedures as the root cause of frequent Sling Fan tripping. 

• Conducted hands-on operator retraining to ensure adherence to optimal startup sequences. 

• Eliminated tripping issues, leading to zero occurrences post-training. 

The Results: Measurable OEE Gains and Increased Processing Capacity 

The implementation of these structured improvements yielded immediate and sustained results, including: 

• OEE Increase: From 85.2% to 93.4% within a 16 weeks. 

• Higher Plant Availability: Reduced downtime due to equipment failures, power losses, and process inefficiencies. 

• Improved Production Output: Enhanced overall maize processing capacity, allowing for increased production of starch-derived products. 

• Greater Workforce Engagement: Training initiatives empowered operators with the skills needed to sustain process improvements. 

What’s the Wait? Apply These OEE Lessons to Your Manufacturing Operations 

This case study highlights the power of a structured, data-driven approach to OEE improvement. Manufacturers across industries can leverage similar principles to optimize their production efficiency. Key strategies include: 

1. Conducting a Detailed Loss Analysis: Identify the biggest contributors to availability, performance, and quality losses. 
2. Leveraging KAIZEN™ & Lean Methodologies: Use problem-solving tools like Value Stream Mapping (VSM), Root Cause Analysis (RCA), and Standardized Work to eliminate inefficiencies. 
3. Implementing Predictive Maintenance Practices: Transition from reactive to Condition-Based and Predictive Maintenance to reduce unplanned downtime. 
4. Training and Engaging Operators: Equip teams with the knowledge and skills to sustain improvements over the long term. 
5. Optimizing Power and Resource Utilization: Ensure robust energy and process management systems to prevent unnecessary disruptions. 

KAIZEN™ Institute as the Leading OEE Consulting Partner 

As global leaders in OEE consulting and Lean transformation, KAIZEN™ Institute brings deep expertise in helping manufacturers unlock higher productivity, reduce costs, and sustain operational excellence. By combining cutting-edge methodologies with practical, hands-on implementation, we deliver measurable and lasting improvements for our clients. 

If your organization is looking to achieve similar OEE breakthroughs, our team of experts is ready to help. Contact us today to schedule an assessment and take the first step toward world-class manufacturing efficiency. 

Boosting OEE: The Future of Smart Manufacturing 

In an era where digital transformation, sustainability, and lean manufacturing are driving competitive advantage, optimizing OEE remains one of the most impactful levers for increasing profitability and operational resilience. By adopting a structured, data-driven approach, manufacturers can achieve sustainable efficiency gains and set new benchmarks for performance excellence. 

KAIZEN™ Institute is committed to being the thought leader in OEE strategy and consulting—helping organizations worldwide achieve best-in-class operational efficiency. 

To learn more about our customized OEE solutions, visit Kaizen Institute Singapore website or reach out to Kaizen Institute Singapore experts today! 

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