Every production line is losing money. The real question is: how much — and can you actually see where it goes?
These losses rarely look like dramatic breakdowns.
They leak out quietly: in micro-stops, extended changeovers, undertrained operators, slow onboarding, and small speed losses that never officially count as downtime — yet erode output every single shift.
The numbers tell the story: a machine designed for 6,000 pcs/h producing only 3,600 means 40% of value simply disappearing. Not in one catastrophic failure — but in thousands of small, invisible events spread across weeks and months. Behind these losses, the same three areas are always responsible: machines, materials, and people.
Machines rarely fail instantly
First a belt loosens slightly, vacuum pressure drops by milliseconds, a micro-signal appears that’s easy to miss. Traditional maintenance offers two bad choices: fix it after the breakdown (always too late) or replace parts on a rigid schedule (often too early). OEE Excellence Pack with PackGuru introduces a third option — condition-based monitoring that detects anomalies before they become failures, turning unplanned downtime into a scheduled Friday afternoon maintenance window.
Flexible Lines
