OEE Calculator

Overview

The OEE Calculator skill provides comprehensive capabilities for calculating and analyzing Overall Equipment Effectiveness. It supports availability, performance, and quality tracking, six big loss categorization, and world-class benchmarking.

Capabilities

• Availability calculation
• Performance rate tracking
• Quality rate measurement
• OEE trending and dashboards
• Six big loss categorization
• Pareto of losses
• Improvement target setting
• World-class benchmarking

Used By Processes

• LEAN-001: Value Stream Mapping
• SIX-002: Statistical Process Control Implementation
• CI-003: Benchmarking Program

Tools and Libraries

• MES integration
• OEE software
• Real-time dashboards
• Data collection systems

Usage

skill: oee-calculator
inputs:
  equipment: "CNC Machine 5"
  period: "2026-01-15"
  shift_data:
    planned_production_time: 480  # minutes
    downtime:
      - type: "breakdown"
        minutes: 30
      - type: "changeover"
        minutes: 20
    ideal_cycle_time: 0.5  # minutes per unit
    total_count: 800  # units
    good_count: 780  # units
outputs:
  - oee_score
  - availability
  - performance
  - quality
  - loss_breakdown
  - improvement_opportunities
  - trend_analysis

OEE Calculation

Formula

OEE = Availability x Performance x Quality

Where:
Availability = Run Time / Planned Production Time
Performance = (Total Count x Ideal Cycle Time) / Run Time
Quality = Good Count / Total Count

Example Calculation

Planned Production Time: 480 minutes
Downtime: 50 minutes
Run Time: 430 minutes
Ideal Cycle Time: 0.5 minutes
Total Count: 800 units
Good Count: 780 units

Availability = 430 / 480 = 89.6%
Performance = (800 x 0.5) / 430 = 93.0%
Quality = 780 / 800 = 97.5%

OEE = 89.6% x 93.0% x 97.5% = 81.3%

Six Big Losses

Loss Category	OEE Factor	Examples
Breakdowns	Availability	Equipment failures
Setup/Adjustments	Availability	Changeovers, warm-up
Small Stops	Performance	Jams, minor issues
Reduced Speed	Performance	Running below ideal rate
Startup Rejects	Quality	Scrap during start-up
Production Rejects	Quality	In-process defects

OEE Benchmarks

OEE Level	Classification	Typical Range
World Class	Best in class	85%+
Good	Above average	70-85%
Average	Typical	60-70%
Low	Needs improvement	40-60%
Poor	Significant issues	<40%

World-Class Targets

Factor	World Class	Typical
Availability	>90%	85%
Performance	>95%	90%
Quality	>99.9%	98%
OEE	>85%	60%

Loss Analysis Process

1. Collect accurate loss data
2. Categorize by six big losses
3. Create Pareto chart
4. Focus on top losses
5. Apply appropriate methodology
6. Track improvement

Integration Points

• Manufacturing Execution Systems
• PLC/SCADA systems
• Quality Management Systems
• Maintenance management (CMMS)