Planned vs Unplanned Downtime — A Strategy Guide TL;DR Planned downtime is scheduled in advance and minimized through optimization (SMED, predictive maintenance). Unplanned downtime is unpredictable and minimized through reliability improvements (real-time tracking,...
Manufacturing Downtime Cost — A 6-Category Framework TL;DRThe true cost of manufacturing downtime has 6 components: lost margin, emergency maintenance, scrap and restart, idle energy, logistics impact, and overtime labor. Most plants only count 1-2 components...
First Pass Yield & RTY for Multi-Station Manufacturing Lines TL;DR First Pass Yield (FPY) measures the percentage of parts passing inspection on the first attempt at a single station. Rolled Throughput Yield (RTY) is the product of all individual station FPYs...
Ideal Cycle Time — Empirical Calibration Method TL;DRIdeal cycle time is the foundation of OEE Performance calculation. Most plants set it incorrectly, causing 5-15% Performance error. The correct method is empirical: use the actual demonstrated best cycle, sustained...
OEE Quality — FPY Tracking Methodology for Manufacturers TL;DRQuality is the third OEE pillar, measuring the ratio of good parts to total parts produced. It is closely related to First Pass Yield (FPY) but measured at line level vs station level. The 4-level FPY...
OEE Performance — How to Detect Micro-Stops and Speed Losses TL;DRPerformance is the second OEE pillar, measuring actual cycle speed vs ideal speed. It captures two distinct loss types: speed losses (sustained underspeed) and micro-stops under 5 minutes. Performance...
OEE Availability — 7 Improvement Tactics Ranked by Impact TL;DRAvailability measures the ratio of run time to planned production time. World-class is 88-90% for discrete manufacturing. Plants moving from manual to real-time tracking typically discover 40-60% of...
The Six Big Losses — Pareto Analysis Framework for Manufacturing TL;DR The Six Big Losses framework, developed by Nakajima as part of TPM, categorizes every manufacturing productivity loss into six categories mapped to OEE pillars. Combined with Pareto analysis, it...
OEE vs TEEP vs OOE — A Decision Framework for Manufacturers TL;DROEE measures performance during scheduled production time. TEEP measures performance against all calendar time (24/7/365). OOE measures performance during operating time (staffed time). Use OEE for...
OEE Formula — 5 Worked Examples from Real Manufacturing Plants TL;DROEE is calculated as Availability × Performance × Quality. This guide walks through 5 fully-worked examples from real plant data: a packaging line at 79.5% OEE, an automotive Tier-2 at 71.3%, a pharma...
