OEE Optimization in the Production of Biochemical Active Ingredients
Manufacturing site for biochemical active ingredients with a single production line
OEE optimization at a manufacturing site for biochemical active ingredients whose single production line had reached its capacity limits. The goal was to make downtime losses transparent and to make better use of available production capacity.
The challenge
The situation
The manufacturing site had reached its capacity limits. Systematic OEE tracking was lacking, which resulted in a lack of transparency regarding downtime losses. Inefficient communication between the process teams and inadequate capacity planning aggravated the problem. Frequent production stoppages caused by time-consuming cleaning processes further disrupted operations. The main objectives were to optimize downtime-loss tracking, to improve communication between the teams, and to reduce cleaning times in order to minimize stoppages.
Our approach
What we delivered
Comprehensive planning of the entire development project through to market launch
Regular status reports and assessment of objective attainment
Weekly project meetings to steer the project team
Introduction of systematic downtime-loss tracking and optimization of capacity planning
Reduction of cleaning times and minimization of production stoppages
The outcome
Results & impact
10% lower production costs
Reduction of production costs by 10 percent through more efficient use of production capacity.
Increased capacity utilization
Higher capacity utilization through improved team coordination and task management.
20% lower project costs
Reduction of project costs by 20 percent within 12 months.
In summary
The optimization led to a 10 percent reduction in production costs and improved capacity utilization. Within 12 months, project costs were reduced by 20 percent.
Related expertise
Lean Manufacturing →
OEE measurability and efficient operations along the production line.
Continuous Improvement Programs →
Systematic downtime-loss tracking and sustainable process control.
Production Transfer & Scale-up →
Better use of production capacity once capacity limits have been reached.
Lean Six Sigma Consulting →
Methodology for reducing downtime losses and production stoppages.
Sources
- https://theentourage.de/case-study/oee-optimierung-biochemische-produktion/ (live case study, accessed 2026-06-14)
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