Planned vs Unplanned Downtime — A Strategy Guide TL;DRPlanned 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;DRFirst 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...
