Posted at 10 January 2019

Festo Improve OEE Using Industry 4.0 Insights

Only one in three manufacturers has a high-availability manufacturing IT strategy or solution in pace. Yet the average manufacturer deals with more than 15 hours a week of downtime, and unplanned incidents are on the rise. When Festo looked into their maintenance programme and processes, they achieved a 15% increase in Overall Equipment Effectiveness (OEE).

festo business improvement


Here’s how they did it:

Scharnhausen, Germany, is the location of one of Festo’s latest production facilities. It’s also the location for an Industry 4.0 initiative which saw state-of-the-art production technology integrated with a forward-looking maintenance programme. The aim was to improve Total Production Maintenance (TPM) and Overall Equipment Effectiveness.

The first step was to equip maintenance engineers with the latest digital technology, to help improve efficiency and provide immediate access to information and resources. The iPad tablets now carried by Festo’s service maintenance personnel are connected by Wi-Fi to over 100 machines, and to the factory’s Manufacturing Execution System (MES). This gives engineers access to information including up to 15 years’ worth of service history, manuals and repair instruction for each machine, notification of pending and current problems, and scheduling of maintenance tasks.

Being able to email and chat while on the move also makes it easier for personnel to collaborate on maintenance tasks, while direct access to the MES allows real-time information uploads and parts stock checks.

In less than six months, Festo’s initiative saw a significant ROI, in four ways:

  • Less travel time
  • Reduced repair time
  • Improved efficiency
  • Improved OEE


The Scharnhausen production facility is also a ‘Learning Factory’, where employees can upskill and acquire practical knowledge. Festo has its own training and consulting division – Festo Didactic – which trains operators on new technology, and continuous learning is part of the culture for all employees.


Read the Complete Article: Know+How Magazine Issue 36 Industrial Digitalisation

There is no denying the prospect of industrial digitalisation is both exciting and daunting in equal measure and no doubt each of you will be at different stages on the road to digital transformation. 

In our latest edition we want to help demystify this familiar buzzword into tangible day-to-day processes. We'll be providing you with an update on the latest news and technology available, taking an in-depth look at Industry 4.0 and all that comes with it, outlining some ways in which the industry can work together.

See pagse 20-21!

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