OEE Calculator

OEE & The 6 Big Losses

Overall Equipment Effectiveness (OEE) factors in Availability, Performance, and Quality to eliminate the 6 Big Manufacturing Losses.

The 6 Big Losses (Hover ‘i’ for details)

• 1. Equipment Breakdowns

  Availability Loss i
  Unplanned Stops: Machine failures, tooling breakdowns, power outages, or component failures causing halts.
• 2. Setup & Adjustments

  Availability Loss i
  Planned Downtime: Changeovers, machine setup, tooling adjustments, warm-ups, and cleaning between runs.
• 3. Small Stops & Idling

  Performance Loss i
  Minor Stops: Brief stops (< 5 mins) caused by misfeeds, sensor blockages, cleaning, or minor jams.
• 4. Slow Cycles / Reduced Speed

  Performance Loss i
  Speed Loss: Equipment operating slower than rated ideal cycle speed due to wear, lubrication, or operator throttle back.
• 5. Production Rejects / Defects

  Quality Loss i
  Scrap & Rework: Defective parts produced during continuous operation requiring scrap or offline rework.
• 6. Startup / Reduced Yield

  Quality Loss i
  Startup Scrap: Off-spec parts produced while warming up machines or stabilizing initial process setup.