Enterprise Resource Planning System Integrated with Overall Equipment Effectiveness for Enhanced Performance Tracking Metrics: Mixed-Methods Case Study of a Nigerian Feed Mill

Many manufacturing companies use Enterprise Resource Planning (ERP) systems to manage their production, maintenance, and logistics, but most of the ERP systems are not able to adequately account for all the losses at the equipment level. This study aimed to integrate Overall Equipment Effectiveness (OEE) into an ERP framework to track performance and apply it in a feed mill in Ibadan, Nigeria. The study used a mixed-method design, survey methods, and production data, which were processed through a custom MATLAB-based OEE calculator for Pareto analysis of downtime causes. It was found that capacity utilisation in the production section ranged from 84.59% to 87.29%, and the overall OEE was 70.75%, which is below the 85% global benchmark, primarily due to performance-related losses. More than 86% of total downtime was caused by target-achievement stoppages and preventive maintenance, which is the typical Pareto pattern. The workforce expansion and automatic bagging methods offer better long-term returns than the silo installation option, which is the earliest to reach the break-even point considering the payback period. It presents the concept of 'utilisation masking ', explaining how the output of the aggregates can mask losses on the equipment, and proposes that integration of OEE with ERP, based on Total Productive Maintenance and Socio-Technical Systems theory, is crucial for moving towards proactive enterprise-wide decisions from shop floor data. The results provide valuable practical information for agro-industrial plants in similarly constrained economies.