More Output from the Line You Already Have
Before buying new equipment, consider this: most production lines are operating at 60–75% of their theoretical capacity. MACH identifies and eliminates the constraints holding your line back.
Production line improvement is often the highest-ROI automation project available to a manufacturer. Instead of spending capital on new machinery, you squeeze more output from existing assets by attacking the constraints that limit throughput. MACH applies lean manufacturing principles and industrial engineering rigour to deliver lasting improvements — not just temporary fixes.
Common Challenges We Solve
- OEE below 75% — significant untapped capacity in existing equipment
- Line imbalance — some stations idle while others are overwhelmed
- Long changeover times limiting flexibility and minimum order quantities
- Excessive scrap, rework, or quality escapes adding cost
- No production data to guide improvement decisions
- Continuous improvement efforts that deliver short-term gains then stall
How We Approach It
OEE Baseline Measurement
Install production monitoring to measure actual OEE across your line and identify where availability, performance, and quality losses are occurring.
Constraint Identification
Apply theory of constraints methodology to identify the single limiting resource on your line — the genuine bottleneck.
Loss Analysis
Categorise and quantify all forms of production loss: planned and unplanned downtime, speed losses, and quality losses.
Improvement Design
Design targeted automation, process, or equipment changes to eliminate the highest-value losses first.
Implementation & Validation
Implement improvements in controlled phases, measuring the impact of each change before proceeding to the next.
What You Can Expect
Increased Throughput Without Capital
Eliminating constraint-based losses regularly increases line throughput by 20–40% without significant equipment investment.
Improved OEE
Most lines we work with improve from 65–75% OEE to 82–90% OEE after a structured improvement programme.
Faster Changeovers
Applying SMED methodology to changeover reduction can cut changeover time by 50–70%, enabling smaller batches and greater schedule flexibility.
Data-Driven Decisions
Production monitoring provides the data foundation for ongoing continuous improvement — moving from gut feel to evidence-based decisions.
Reduced Scrap & Rework
Automated quality monitoring and tighter process control reduce defect rates and eliminate rework loops from your production flow.
Operator Engagement
Visible production data and clear improvement targets engage operators in the improvement process, sustaining gains over time.
Who We Work With
Frequently Asked Questions
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