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By Tony Gregory
Overall Equipment Effectiveness (OEE) is a key performance indicator for any packaging automation system. In high-speed environments such as liquid filling lines, every micro-stop, changeover, or quality deviation directly affects productivity and profitability.
Whether you're managing pharmaceutical bottle unscramblers, cosmetic packaging machinery, or food and beverage filling lines, understanding what causes OEE to drop is essential for operational excellence.
This article explores common, realistic scenarios that negatively impact OEE and proposes concrete solutions to maintain optimal performance.
1. Bottles with Complex or Unstable Designs
Bottles with unusual shapes (oval, asymmetrical, tall and narrow) are more prone to tipping, misalignment, jamming, or instability—especially during transfers and curves in unscramblers, fillers, or conveyors.
Impact on OEE: Increases micro-stops and machine jams, reducing performance and quality.
Solution: Optimize bottle design in collaboration with suppliers; integrate puck handling systems or adequate transport systems like vacuum conveyors. Adapt line layout to minimize instability (e.g., fewer curves and transfers).
2. Frequent Format Changes Within the Same Line
Lines that handle multiple SKUs (different bottle sizes or caps) need constant adjustments between runs.
Impact on OEE: Increased setup/changeover time significantly reduces availability.
Solution: Invest in quick-change tooling and recipe-based automation. Implement SMED (Single-Minute Exchange of Dies) practices. Opt for automatic changeover systems like the POSIFLEX unscrambler or POSIMAT robotic bottle unscrambler.
3. Variation in Bottle Quality from Different Suppliers
Even within specification, small differences in bottle height, neck finish, or wall thickness can cause equipment malfunctions.
Impact on OEE: Higher reject rates reduce quality, while frequent adjustments lower availability.
Solution: Standardize supplier specifications and perform incoming quality checks. Work with fewer, more consistent bottle suppliers and share monthly quality reports to make them accountable.
4. Operators with Low Training or Lack of Technical Know-How
Untrained or newly hired operators often misinterpret alarms or make errors during cleaning and changeover.
Impact on OEE: Leads to downtime and human errors, reducing both availability and performance.
Solution: Create structured training programs, visual SOPs, and guided digital instructions. Choose machinery with intuitive plug-and-play systems and minimal setup requirements.
5. Mismatch in Speed or Capability Between Machines
A line is only as strong as its slowest machine. Inconsistent speed across fillers, cappers, and case packers creates bottlenecks.
Impact on OEE: Bottlenecks and accumulation overflow reduce performance.
Solution: Balance speeds using buffer systems and dynamic line control. Coordinate specifications with both upstream and downstream equipment manufacturers, and hold them accountable for bottle flow consistency.
6. Environmental Conditions Affecting Packaging
Factors like humidity, temperature, and dust can disrupt label adhesion, affect bottle rigidity, and interfere with sensors.
Impact on OEE: Causes jams, errors, and rejects—affecting quality and availability.
Solution: Maintain proper HVAC and air filtration systems. Use anti-static materials and components rated for the environmental conditions of your facility.
Conclusion: Maximizing OEE Across the Entire Line
Achieving high OEE in packaging automation requires a holistic approach—balancing machine capability, operator training, bottle design, and environmental stability. From automatic bottle unscramblers to air conveyor systems, every detail matters. Companies looking for the best bottle unscrambler manufacturer or the most proven unscrambling technology should consider integrated solutions that reduce variability and optimize line flow.
Whether you're in Europe or the USA, choosing a partner with deep expertise in packaging machinery and packaging automation lines is key to long-term efficiency.