Total Productive Maintenance TPM Software for Overall Equipment Effectiveness
OEE Software to SOLVE problems
not just identify them
The big difference between this and any other Lean OEE software
is that your Systems2win templates provide you with the tools you need to SOLVE PROBLEMS
not just identify them.
Your OEE Excel template has Andon colors that make it childishly obvious where your problems are.
Just look for pink and yellow cells that highlight measures outside of your user-defined Andon Tolerance levels
You can filter your reports in any way to drill down to greater levels of detail for anything that catches your eye.
You have all the power of Excel to generate any type of chart to graphically illustrate the problems that you find.
And then once you have used this powerful OEE toolkit to identify and illustrate your problems...
the next obvious question becomes...
"so what are we going to do about that?"
That is where most oee software leaves off... perhaps continuing to ask you if you would like to generate yet another type of chart to further illustrate the problem that you have already clearly defined.
This OEE software comes with
the tools to solve the problems that you identify
When you own all 4 bundles of Systems2win templates, you have the tools you need to actually solve the problems that your TPM analysis has identified. Depending on the nature of your top priority problems, you might use...
- The Preventive Maintenance Checklist
- The Standard Work Combination Sheet for SMED Quick Changeover improvement or work load balancing
- The Machine Load Balancing worksheet to balance your machine loads
- Job Instructions, Standard Procedure template, or TWI tools to improve employee training (which is often among the root causes for those unacceptable numbers that keep showing up in pink)
- The Cross Training Matrix to ensure that someone is cross trained to fill in for every position (without a noticeable down-spike in OEE Performance and Quality every time that someone gets sick or takes a vacation)
- The 5S Scorecard to ensure that all work areas are clean and organized
- The Standard Work Audit for a systematized way to ensure that the most challenging 4th and 5th S's stay front and center for years (not just days) after your initial 5S push
- Value Stream Mapping to help with the decision of where to focus your attention (including OEE attention) on those segments of the process that will yield the greatest return on your efforts
- Kaizen Events and A3 Reports and Gantt Chart Project Plans as field-proven systematic approaches to problem-solving
- FMEA to proctively idenfity and minimize potential risks
- Root Cause Analysis Fishbone Diagram to brainstorm creative problem-solving ideas
- QFD House of Quality and Cause & Effect Matrix and an entire bundle of Six Sigma tools to ensure that you are solving problems that your customers actually care about
Wouldn't it be depressing to just be told about all of the problems you have?
Wouldn't it be more helpful to have an entire suite of tools to actually solve the problems that your OEE software identifies?
Integrate your OEE data
You can collect data for each Work Center in any one of 3 ways: (which can vary by Work Center)
- Enter data directly into a Log worksheet
- Collect data manually - then type it into a Log worksheet
- Use Automated Data Collection - using a scratch workbook to convert the data into a format that matches the Log worksheet - then import the data to a Log Worksheet
Import to your OEE software
And then with a click of a button, you can import your data.
You can import data from multiple data collection workbooks - into one shared OEE Data repository.
Analyze your TPM OEE data
Filter your data with all of the power of Excel's Filter features.
Push a button to analyze your source data Log -
easily generating Pareto Charts and any other Excel chart.
Push another button to analyze your shared OEE Data repository -
with trend charts, OEE charts for your primary filter, and an OEE Waterfall Chart for any row of data.
Push the Andon button to highlight cells for quick troubleshooting...
Cells with pink background are outside of your user-defined tolerances.
Yellow are more than half way to the tolerance level.
If your company already owns OEE software
Your people are probably already so familiar with Excel that they might want to import your raw data to your Systems2win OEE template to supplement the standard analyses provided by the legacy OEE software that your company might already own.
Maybe you'll catch something you missed when you analyze your OEE data from another angle.
Or maybe some of your work centers will prefer our Excel-based Daily Log to capture data that can then be easily integrated with any other OEE software.
If you purchase our Six Sigma tools for other reasons - why not? You can just view our OEE template as a really nice "gift with purchase".
Bookmark = Training
OEE Training & Demo Videos
Make sure your sound is on
Bookmark = Glossary
Glossary of terms
for TPM Total Productive Maintenance and OEE Overall Equipment Effectiveness
Use Ctrl+F to find keywords
Also see our Lean Dictionary
OEE Overall Equipment Effectiveness = Availability * Performance * Quality
Framework for measuring process efficiency - by breaking it into 3 constituent components.
World class benchmark >85%
Availability = Net Operating Time / Planned Uptime
A pure measure of Uptime, excluding the effects of Quality, Performance, and Planned Downtime Events.
World class >90%
Peformance = Ideal Cycle Time / Actual Cycle Time
A pure measure of speed, excluding the effects of Quality and Availability.
World class >95%
Quality = Good Units Produced / (Good Units Produced + Rejects)
A pure measure of Process Yield, excluding the effects of Availability and Performance.
World class >99% (and often >99.9%)
Work Center = One machine, or a group of assets reported on a single Daily Log, and treated as one entity for OEE reporting.
It is common for each Work Center to maintain their Daily Log in a separate Excel workbook - then copy & paste to a central OEE Data workbook that summarizes the OEE for several interdependent Work Centers.
Product or Product Family = What is being produced
For OEE purposes, it is often sufficient to report by product family (rather than specific product or part number).
Good Units Produced = Units produced that meet quality standards - without rework.
Rejects = For OEE - any unit that not does meet First Pass Yield quality standards is a reject.
If rework might be performed later to attempt to salvage some value - then there is no question - rework is just another category of reject.
If rework is successfully performed during that same shift - then there are 2 schools of thought, and your organization needs to choose one of them, and use it consistently:
1) The reworked units are simply reported as Rejects.
2) The reworked units are reported as both Rejects and Good Units Produced.
Reject Category = User-defined reasons for reject
Some companies use this field exclusively for Reject Categories - such as:
- Reject produced during Regular Production
- Startup & Change Over rejects
Others also include Reasons - or more details, such as:
- Scrap due to temperature variance
- Rework that surfaced downstream
- Rework that was handled in process
- Rejects that might be reworked later
Available Time = Total minutes available for work.
Don't subtract meals or breaks or planned downtime.
Do subtract downtime beyond team's control. For example: weather, natural disaster...
Usually 480 mins per 8 hour shift.
If the shift will be making more than one product, then split Available Time into time per Product or Product Family, being careful to ensure that the total adds up to the total Available Time for that Shift.
Yes, it is permissible to record Available Time for the entire day, rather than by shift, but why? Don't each of your shifts report their time and production and rejects? Why would you want to obscure shift details when doing your analyses?
Planned Downtime = Deliberate downtime that is excluded from OEE calculations.
Examples: Planned maintenance,
equipment shut down during meals, breaks or meetings,
planned downtime because there is no customer demand
(and one of the foundational lean principles is to produce no faster than the pace of actual customer demand)
aka: Planned Production Time, Net Available Time, Scheduled Time, Running Time
It is very unfortunate that there is no agreed-upon term for this important concept that is so foundational to OEE.
OEE starts with this amount of time, (if that's not foundational, what is?),
and yet we could not find two books or software packages that called it the same name.
Like all Systems2win templates, you can use Insert Comment to add your own user-defined help to supplement (rather than replace) the standard Systems2win pop-up help (which will still be available in addition to your user-defined help - thereby making it easy for your users to translate your own in-house terminology with the terminology used in Systems2win's on-line training pages)
Loading Effectiveness = Planned Uptime / Available Time
Some companies also measure:
Utilization = Planned Uptime / Total Possible Available Time (1440 mins per day)
TEEP Total Equipment Effectiveness Performance = OEE * Utilization
Systems2win has chosen not to track Utilization and TEEP in the standard template because:
- The entire concept of maximizing equipment utilization only fits lean philosophy in the rare situation where customer demand chronically exceeds capacity.
- Maximum Possible Available Time becomes confusing and difficult to track in diverse reporting environments
(as you will quickly discover if you ever work a second shift and attempt to program this metric with User Defined Calcs)
- TEEP is so easy to calculate once you know how many shifts are being worked per day. So we suggest simply using a hand calculator to calculate TEEP in those rare moments that you want to analyze it.
Downtime Threshold = Maximum amount of time production can be stopped before it must be recorded in Log
Anything that stops production longer than this number of minutes must be recorded in the Lost Time Log, and will therefore be included in Downtime Loss.
Shorter minor stoppages will be reflected in Performance Loss.
Downtime Loss = Change Overs + Standby + Unplanned Downtime
Any event that stops Planned Uptime longer than the number of minutes defined as the Downtime Threshold must be recorded in the Lost Time Log. Everything recorded in the Lost Time Log is included in Downtime Loss, which affects the Availability portion of OEE. Shorter minor stoppages get reflected in the Performance portion of OEE.
Setups, change overs, and adjustments to equipment.
Please note that Change Overs are NOT Planned Downtime - even if they are pre-planned.
Change Overs ARE included within OEE calculations as reduced Availability - and SMED Quick Change Over projects are among the most popular TPM activities resulting from OEE analysis.
That's why your Systems2win template breaks Change Overs into their own sub-category - rather than obscuring them in one big glob of Downtime Loss.
Production stopped due to:
- being starved by unavailability of upstream materials
- or backed up by unavailability of downstream production or storage capacity
You won't find Standby in very many OEE books, but several of our customers find it essential.
Especially when several Work Centers are grouped together in a highly interdependent production line or cell - it is very helpful to pinpoint your problem by ascribing Unplanned Downtime to only the one Work Center that caused all of the other Work Centers to be down at the same time.
The one Work Center with the root problem has Unplanned Downtime, and all of the other affected Work Centers have Standby time.
Anything other than Change Overs or Standby that stops production longer than the number of minutes defined in the Downtime Threshold.
Examples: Various types of equipment failure, operator unavailability...
Net Operating Time = Planned Uptime - Downtime Loss
Productive time available after downtime losses are deducted.
We have seen some books and software incorrectly abbreviate "Net Operating Time" to "Operating Time".
Operating Time has its own definition. Operating Time = Available Time - Planned Downtime - Change Overs
and is essential to the less popular calculation of NEE Net Equipment Effectiveness - which is almost identical to OEE, but Availability does not include Change Overs.
NEE = ((Operating Time - Standby - Unplanned Downtime)/Operating Time) * Performance * Quality
If you personalize the User Calcs in your Systems2win template to calculate NEE - then you will appreciate that we did not incorrectly abbreviate "Net Operating Time" to just "Operating Time".
Ideal Operating Time = (Good Units Produced + Rejects) * Cycle Time per unit
Does not penalize for quality Rejects
Ideal Cycle Time
If the Cycle Time Unit of Measure is seconds, minutes, or hours,
then this is the theoretical fastest time to produce one unit
If the Cycle Time Unit of Measure is ppm parts per minute,
then this is the theoretical fastest Run Rate (parts per minute)
Some companies use the Nameplate Capacity as a less-than-perfect estimate of Ideal Cycle Time
(Nameplate Capacity = the maximum speed estimate made by the engineers that made the machine)
but if the engineers guessed a little low - then then your actual performance might sometimes exceed their estimate of fastest machine speed - which then results in an OEE Performance rating of over 100%.
Technically, no OEE component metric should ever exceed 100%, but as long as you consistently apply the same nameplate capacity over time, your OEE measure will still be useful for comparing OEE improvement on that machine.
This is a good example of why OEE is intended to be used only to evaluate the progress of a single Work Center - and is NOT intended to compare the efficiency of different Work Centers against each other.
aka Speed Loss, Performance Time Loss
The amount of time lost due to Performance inefficiencies, such as idling, minor stoppages, machine running at reduced speed...
Any slow downs or minor stoppages less than the Downtime Threshold will show up in Performance Loss.
Performance Time = Net Operating Time - Performance Loss
Productive time before Quality Losses are deducted.
Quality Time Loss = Rejects * Cycle Time per unit
Time lost due to quality problems.
aka Effective Time, Fully Productive Time, Net Productive Time
Actual productive time after ALL losses are subtracted.
The true bottom line of your process efficiency.
Andon = A system to draw attention to problems
When you click the Andon button in your Systems2win OEE template,
numbers outside of your user-defined Andon Tolerance levels will appear pink,
and values halfway close will appear yellow.
Waterfall Chart = Chart that graphically depicts each OEE element
starting with Available Time, being reduced by each OEE Time Loss, and ending with Productive Time
Your Systems2win OEE template can instantly create a Waterfall Chart for ANY row that you want to analyze
which is something that most OEE software can't do...
which is one reason why some people import their existing OEE data to their Systems2win template for futher analysis.
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- Like always, be sure to refer to the Help worksheet of your Systems2win template,
which always contains valuable help and training specific to each template.
Free trial of OEE template
is available upon special request
This OEE template comes bundled with all the other Six Sigma tools
and you can empower every team member