The Flow that is Broken
An operator raised a problem at 5am. Within one day it was solved. Three weeks later I watched the same instinct fail completely, because the system to catch it did not exist. Same people. Same problem. Different system.
Are we Winning or Losing?
I've asked this question in a lot of plants, to a lot of people. The answers are almost always the same. Not wrong. Not evasive. Just untethered from anything you could verify in the moment.
The Number that Lies
OEE cannot exceed 100%. So when I found 106.4% on a packaging line, I went looking for the error. What I found instead was a system designed to limit questions rather than surface performance.