OEE & PERFORMANCE MONITORING
The first OEE number you calculate is always wrong
Almost every plant that starts measuring OEE gets a number that flatters it. Short stops go uncounted because nobody logged them. Performance is measured against a rate that was never realistic. Quality is assumed rather than measured. The result is a figure that looks respectable, cannot be compared with anyone else's, and does not move when things genuinely improve. An OEE number is only useful if its three components are measured honestly and separately — because that is what tells you which of the three is actually costing you.
Measured properly, component by component
Availability, measured not estimated
Run time and stop time captured automatically from the machine, including the short stops that manual logging always misses and that often account for most of the loss.
Performance against a real rate
Actual output compared with what the machine should have produced in the time it was running, using a rate grounded in the process rather than an optimistic nameplate figure.
Quality from measurement
The quality component derived from measured results against specification, not assumed to be a constant.
Per machine and per line
OEE for every machine individually and aggregated by line, so the plant figure can always be decomposed into the machines that produced it.
Trends over time
Performance tracked across days, weeks and months, so improvement can be demonstrated and drift can be spotted before it becomes normal.
One definition, every machine
The same calculation applied consistently everywhere, which is what makes comparison between machines, lines and — for a group — between plants meaningful.
How it works
Define what good looks like
We agree the target rate, what counts as planned versus unplanned downtime, and how quality is measured. This is the part that determines whether the number is trustworthy.
Collect the components separately
Availability, performance and quality data are captured independently from the machines and quality records, rather than being inferred from one another.
Report at every level
A single OEE figure for management, the three components for engineers, and the underlying stops and measurements for whoever needs to act.
Technical detail
Availability comes from machine state captured by the acquisition layer, performance from counted output against the agreed rate over actual run time, and quality from measured results against specification. Each component is stored separately so the aggregate can always be decomposed and audited. Calculation periods, shift boundaries and downtime classification rules are configured per plant.
GET AN OEE NUMBER YOU CAN TRUST
Tell us how OEE is calculated in your plant today. We will tell you honestly what it is probably missing.