Background: Overall Equipment Effectiveness (OEE) is an internationally accepted metric for quantifying manufacturing productivity, which combines Availability, Performance, and Quality into a single composite score. Despite extensive literature on OEE in automotive and food manufacturing, empirical studies on grease and lubricant manufacturing, particularly in developing economies, remain scarce. Methods: This study presents a primary data case study of Siddharth Grease & Lubes Pvt. Ltd. (SGLPL), a contract grease manufacturer at IMT Manesar, Haryana, India. Twelve months of production records (April 2024–March 2025), First Time Right (FTR) quality data, formal preventive maintenance (PM) documentation (MM-F-003, MM-F-007), and daily machine check sheets were analyzed. The OEE components were calculated using the ISO 22400-2 (2014) formulas. Plan deviations were categorized using Pareto analysis, and the PM system was evaluated against Total Productive Maintenance (TPM) best practice criteria. Results: Across 3,134 grease batches produced during the study period, the FTR Quality Rate was 100% (zero reworks, zero rejections), against an internal target of >95%. Of the 41 documented production plan deviations, none were attributable to machine breakdowns. All deviations were supply chain-related: Holding Tank unavailability (53.7%) and raw/packaging material shortages (46.3%). The estimated OEE was 95.6% (availability 97.8%, performance 97.8%, quality 100.0%), exceeding the internationally recognized world-class threshold of 85% for all three components. Conclusion: The findings empirically demonstrate that a comprehensively implemented PM regime encompassing 68 assets across four maintenance frequency tiers, supported by shift-level daily check sheets, can sustain world-class OEE in a high-complexity batch manufacturing environment. The residual OEE improvement frontier in a PM-mature facility shifts from maintenance to production scheduling and supply chain management. This study provides original primary evidence from the underrepresented grease manufacturing sector and offers a replicable PM effectiveness evaluation framework for similar process manufacturers.
Overall Equipment Effectiveness (OEE); Preventive Maintenance; Grease Manufacturing; First Time Right (FTR); Total Productive Maintenance (TPM); Batch Processing; Production Schedule Adherence; India; Case Study.
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