Advancing operational excellence with OEE 2.0: a case study on Nutella packaging line at Ferrero

In high-volume and complex production settings, operational excellence is essential. This thesis discusses the implementation of Overall Equipment Effectiveness (OEE) 2.0 in the context of Industry 4.0 with reference to Nutella Packaging Line 9 of Ferrero's Alba plant. OEE 2.0 improves upon conventional OEE measurements by incorporating sophisticated data analytics and real-time monitoring to gain a deeper insight into equipment performance and production efficiency. The research starts with the theoretical background of OEE and how it evolved to OEE 2.0, then a detailed survey of the state-of-the-art in the application of OEE 2.0. The research provides a complete OEE 2.0 development and deployment framework, which includes finding the production line configurations, developing graphical user interfaces to perform analysis, and deploying the production software. A case study on Nutella Packaging Line 9 demonstrates the real-world implementation of OEE 2.0. The analysis defines major inefficiencies, including high micro-stoppages and material shortages, and focuses intervention to enhance performance. The outcome is noteworthy improvement in operating efficiency, with a substantial rise in OEE and decrease in downtime. The document concludes with the description of the extended implications of OEE 2.0 and the formulation of Overall Asset Effectiveness (OAE), proposing the incorporation of financial, operational, and sustainability metrics to gain long-term success in contemporary manufacturing setups.