Continuous dyeing systems are highly sensitive to short, recurring losses that gradually erode effective capacity. Although Overall Equipment Effectiveness (OEE) is widely reported in textile operations, it is rarely operationalized as a control mechanism. This study designs and tests an OEE-driven closed-loop governance framework in an active CPB-Thermosol dyeing department in Bangladesh over a six-month period (January – June 2024). Machine-level time was structured using a standardized loss architecture, with OEE components mapped to the Six Big Losses to enable mechanism-level diagnosis. Variation in performance was found to be predominantly availability-driven: setup and adjustment losses (2,331.02 h) far exceeded breakdown losses (248.17 h), while Performance and Quality remained stable. Monthly OEE ranged from 41% to 63%, closely tracking Availability (51–65%). Structured changeover control through SMED reduced average setup duration from 315 to 145 min (~54%). Concurrently, reprocess rates declined and On-Time Delivery improved from 55% to 81%. The findings demonstrate that in high-mix continuous dyeing, setup readiness and changeover discipline deliver greater gains than breakdown reduction alone. By integrating measurement, signaling, verification, and prevention within one operating cycle, the framework reframes OEE as a daily governance backbone rather than a standalone KPI.
Rahman et al. (Thu,) studied this question.