MANUFACTURING PROCESS RELIABILITY METRIC

2.1.1 OVERALL EQUIPMENT EFFECTIVENESS (OEE)

Published on April 16, 2009
Revised on August 3, 2016

DEFINITION
This metric is a measure of equipment or asset performance based on actual availability,
performance efficiency and quality of product or output when the asset is scheduled to operate.
Overall equipment effectiveness (OEE) is typically expressed as a percentage.

OBJECTIVES
This metric identifies and categorizes major losses or reasons for poor asset performance. It
provides the basis for setting improvement priorities and beginning root cause analysis. OEE
also fosters cooperation and collaboration between operations, maintenance and equipment
engineering to identify and reduce and/or eliminate the major causes of poor performance.
Maintenance alone cannot improve OEE.

FORMULA
Overall Equipment Effectiveness Formula
Overall Equipment Effectiveness (%) =
Availability (%) × Performance Efficiency (%) × Quality Rate (%)

Availability Formula
Availability (%) = [Uptime (hrs) × 100] / [Total Available Time (hrs) – Idle Time (hrs)]

Uptime Formula
Uptime (hrs) = Total Available Time (hrs) – [Idle Time (hrs) + Total Downtime (hrs)]

Total Downtime Formula

Total Downtime (hrs) = Scheduled Downtime (hrs) + Unscheduled Downtime (hrs)

Performance Efficiency Formula

Performance Efficiency (%) =
[Actual Production Rate (units per hour) / Best Production Rate (units per hour)] × 100

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Quality Rate Formula
Quality rate % =
[(Total Units Produced – Defective Units Produced) / Total Units Produced] × 100

COMPONENT DEFINITIONS
Actual Production Rate
The rate at which an asset actually produces product during a designated time period.

Availability
The percentage of the time that the asset is actually operating (uptime) compared to when it is
scheduled to operate. Also called operational availability.

Best Production Rate

The rate at which an asset is designed to produce product during a designated time period or
the demonstrated best sustained rate, whichever is higher.

Defective Units Produced

The number of unacceptable units produced during a time period (e.g., losses, rework, scrap,
etc.).

Downtime Event
An event when the asset is down and not capable of performing its intended function.

Idle Time
The time an asset is idle or waiting to run. The sum of the times when there is no demanded
administrative idle time (e.g., not scheduled for production). Does not include equipment
downtime (scheduled or unscheduled) and no feedstock or raw materials.

Performance Efficiency (Rate/Speed)

The degree to which the equipment operates at historical best speeds, rates and/or cycle times.

Quality Rate
The degree to which product characteristics meet the product or output specifications.

Scheduled Downtime
The time required to work on an asset that is on the finalized weekly maintenance schedule.

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Scheduled Hours of Production
The amount of time an asset is scheduled to run (e.g., total available time, less idle time and
less scheduled downtime).

Total Available Time

Annual Basis: 365 days/year x 24 hours/day = 8760 hours per year (Note: The addition of one
more day per year must be made for leap year.) Daily Basis: 24 hours

Total Units Produced

The number of units produced during a designated time period.

Unscheduled Downtime
The time an asset is down for repairs or modifications that are not on the weekly maintenance
schedule.

Uptime
The amount of time an asset is actively producing a product or providing a service. It is the
actual running time

QUALIFICATIONS
1. Time Basis: See options below.
Real Time – Hourly or per operating shift
Daily – Summary report of OEE performance
Period Trending – Daily, weekly, monthly, quarterly and/or annual comparisons
2. This metric is primarily used by maintenance, reliability, production and industrial
engineers to capture asset performance data in order to identify improvement
opportunities. It is also used by operations, maintenance and plant engineers as a
relative indicator of asset performance from period to period in order to evaluate
equipment stability and potential capacity for the purposes of production scheduling and
capital investment justification.
3. Caution should be used when calculating OEE at a plant or corporate level. OEE
percentage is a better measure of specific equipment effectiveness.
4. OEE is not a good measure for benchmarking assets, components or processes because
it is a relative indicator of specific asset effectiveness over a period of time.

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 5. The OEE percentage should be used primarily as a relative internal improvement
measure for a specific asset or single-stream process.
6. OEE is not a measure of maintenance effectiveness since most factors are not within the
control of the maintainers.
7. If planned and scheduled maintenance is performed during idle time (e.g., when there is
no demand for the asset), the time is not considered downtime. Note: This can result in
misleading production availability values if demand increases, reducing or eliminating
the opportunity to do planned and scheduled maintenance while the asset is idle.
8. The performance efficiency value cannot exceed 100%. To ensure this does not happen,
the best production rate must be specified correctly. When determining best speed, rate
or cycle time, plants must evaluate this based on historic information and whether or
not the best speed is sustainable. Typically, time basis is the prior year. Sustainability
varies by type of asset, but typically is greater than four hours with good quality
production or four days with large process plants.
9. The quality rate should be first pass first time, meaning quality standards are met at the
time of manufacturing without the need for rework.

SAMPLE CALCULATION
An example of the OEE percentage calculation based on OEE data for one day (24 hours) for
Machine D operation is shown in Table 1 on the following page.

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 Table 1. Example Calculation of OEE

Components Data Comments

Total available time 24 hours 24 hours in one day
Idle time 8 hours Not required eight hours per day
Scheduled downtime
No production, breaks, shift change, etc. 0.66 hours Meeting & shift change
Planned maintenance 1.00 hours Monthly PM
Total scheduled downtime 1.66 hours
Unscheduled downtime
Waiting for operator 0.46 hours Operator distracted, on other tasks
Failure or breakdowns 0.33 hours Mechanical drive coupling
Set-ups & changeover 0.26 hours Two size changes
Tooling or part changes 0.23 hours Screw station bits
Startup & adjustment 0.30 hours First shift Monday
Input material flow 0.50 hours Waiting for raw materials
Total unscheduled downtime 2.08 hours
Total downtime (scheduled + unscheduled) 3.74 hours 1.66 + 2.08 = 3.74 hours
Uptime 12.26 hours (24 – 8) – 3.74 = 12.26 hours
Availability 76.63% 12.26 / (24-8) x 100 = 76.63%
Performance efficiency losses (Count)
Minor stops 10 events Machine jams
Reduced speed or cycle time 100 v.167 units Design rate: 12.5 units/hour
Performance efficiency 59.88% (100 / 167) x 100 = 59.88%
Quality & yield losses (Count)
Scrap product/output 2 Waste, non-salvageable
Defects, rework 1
Yield/transition 5 Startup & adjustment related
Rejected units produced 8 2+1+5=8
Good units produced 92 100 – 8 = 92 good units
Quality rate 92% (92 / 100) x 100 = 92%
Overall equipment effectiveness 42.21% 76.63 x 59.88 x 92.00 = 42.21%

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Machine D averaged 42.21% in the current period. Assuming that Machine D OEE averaged
50.2% year-to-date and 45.06% in the prior period, an OEE trending downward warrants a
review and analysis to understand the root causes and to identify and prioritize opportunities for
improvement.

Total Available Time (365 days x 24 hours per day)

Idle Scheduled
Availability

Scheduled Hours of Production

Time Downtime
Unscheduled
Uptime Hours of Actual Production
Downtime

Best Production Rate

Speed

Speed
Actual Production
Losses

Actual Production
Quality

"First Time
Pass" Quality
Saleable Losses
Production

Figure 1. Overall Equipment Effectiveness Timeline

BEST- IN- CLASS TARGET VALUE

85% to 100% batch type manufacturing
90% to 100% continuous discrete manufacturing
95% to 100% continuous process
Availability >90%
Quality >99%
Performance >95% equals a 85% to 100% OEE

CAUTIONS
Caution should be used when calculating OEE at a plant or corporate level. OEE percentage is a
better measure of specific equipment effectiveness. To calculate OEE at a plant level you must
take each element to its basic form before combining availability, quality and performance since
each element is a percentage. OEE is not a good measure for benchmarking assets,

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components or processes because it is a relative indicator of specific asset effectiveness over a
period of time.

The OEE percentage should be used primarily as a relative, internal improvement measure for a
specific asset or single-stream process. OEE is not a measure of maintenance effectiveness
since most factors are not within the control of the maintainers.

If planned and scheduled maintenance is performed during idle time (e.g., when there is no
demand for the asset), the time is not considered downtime. Note: This can result in misleading
production availability values if demand increases, reducing or eliminating the opportunity to do
planned and scheduled maintenance while the asset is idle. The performance efficiency value
cannot exceed 100%. To ensure this does not happen, the best production rate must be
specified correctly. OEE cannot exceed 100%.

HARMONIZATION
This metric has not been harmonized with European standard EN 15341: Maintenance
Indicators.

REFERENCES
Abe, T. (2007). TPM encyclopedia - keyword book. Tokyo, Japan: Japan Institute of Plant
Maintenance.

Hansen, R. C. (2001). Overall Equipment Effectiveness – A Powerful Production / Maintenance

Tool for Increased Profits. South Norwalk, CT: Industrial Press, Inc.

Hartmann, E. H. (1992). Successfully Installing TPM in a Non-Japanese Plant. Allison Park, PA:
TPM Press, Inc.

MacInnes, J. (2002). The Lean Enterprise Memory Jogger. Salem, NH: Goal/QPC.

Raupp, R. (n.d.). Asset Utilization Measures. Chicago, IL: A.T. Kearney.

The Productivity Development Team. (1999). OEE for Operators: Overall Equipment
Effectiveness. Portland, OR: Productivity Press.

Williamson, R. W. (2006). Using Overall Equipment Effectiveness: The Metric and the Measures.
Columbus, NC: Strategic Work Systems, Inc.

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