Case Study
You've Got (World Class) Mail: How Royal Mail Achieved a 20-Point OEE Improvement with TrakSYS
Improvement to OEE achieved in six months
To get a TrakSYS pilot project up and running, with results
Monitoring of maintenance activity frequency to offset costs and optimize performance
Having visual information about the performance of our equipment is an essential part of our WCM initiative at the Royal Mail. We had a paper-based system for capturing performance losses. This was time-consuming, and the accuracy of the information was often questioned. The TrakSYS solution deployed by ITI Group has given us the real-time data we needed with trusted accuracy. We did not stop there, the system has been further developed to assist us on our WCM journey. The application is effortless to use, and the operators have really taken to it.
The Company
Royal Mail plc is an international postal and logistics business operating across 40 countries, including 36 in Europe and eight states in the Western United States and Canada following recent acquisitions. Originating in 1516, Royal Mail now delivers over 80 million pieces of mail every working day across the United Kingdom.
The Challenge
In 2008, Royal Mail launched its World Class Mail initiative, built around the ten pillars of World Class Manufacturing (WCM). The program began in just three mail centers and grew to involve most of Royal Mail's mail and distribution centers over time. As the WCM journey progressed, the team recognized they needed a software platform to sustainably track and improve performance.
Royal Mail had no efficient way to track and compare OEE across facilities, no real-time method for analyzing available data, and operators were spending excessive time manually categorizing downtime events.
The Solution
To close these gaps, Royal Mail partnered with Parsec Automation, LLC certified partner ITI Group to design and implement a TrakSYS rollout. The solution delivered real-time information with accuracy and gave teams the functionality needed to support the WCM journey, including intuitive operator interfaces built for simple interaction and instant feedback.
Real-time KPI reports covering OEE, TEEP, and MTBF were made available to Royal Mail staff through the TrakSYS interface, accessible from any web-enabled device. TrakSYS was also integrated with Royal Mail's existing SAP ERP system, helping teams optimize production and maintenance schedules.
The Impact
- Achieved a 20-point improvement to OEE in six months
- Gained real-time visibility into various mail centers
- Facilitated operator engagement and platform adoption
- Got a TrakSYS pilot project up and running in one day, with results
- Established KPIs across the enterprise
- Began monitoring the frequency of maintenance activities to offset costs and optimize performance
- Gained visibility into losses
Get the Full Royal Mail Success Story
See how ITI Group and TrakSYS helped Royal Mail achieve a 20-point OEE improvement in six months.
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