OEE Template

Total Productive Maintenance TPM Software for Overall Equipment Effectiveness

OEE Toolkit to solve problems

(not just identify them)

The big difference between this and any other Lean OEE software

is that you are empowered with all of the tools that you need

to solve downtime problems, not just identify them.

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videos

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prep

Prepare to use your

OEE template

Before getting started

Launch your team

using the same tools and systems that you use to launch every team for continuous process improvement

Train your users

Personalize your template

Your leaders should have already personalized your workbook to hide or show the sheets that you will need:

• If a workbook will be used only for OEE Analysis, then the unused Log sheet should be hidden.
• If a workbook will be used only as a data collection Log, then the unused OEEData sheet should be hidden.
• If a workbook will have more than one Log sheet, then use the special Systems2win menu > Copy Sheet utility to copy the sheet

  Example: If some of your Work Centers gather data using pen and paper, that data can be transcribed directly into the workbook that is used for Analysis, which would have one Log worksheet per Work Center.

Your leaders should have already personalized the DV sheet in your workbook with:

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how

How to use your

OEE tracking spreadsheet

Find and open your template

Save your working document

following the usual document storage and naming conventions established by your leaders

Open a Blank Sheet

Rename your new sheet.

If English is not your preferred language

Switch to your language, just like every Systems2win Excel template.

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Now you are ready to start using your

OEE Calculation Spreadsheet

Enter header data

At the top of each Log and/or OEEData sheet, enter data in the header fields.

Collect your OEE data

On each Log sheet

On each Log sheet - data is entered in 3 sections and you can click the Navigation links to quickly move between sections

Top Log entries

Make a single log entry of Good Units produced for each combination of Shift and Product/Family.

If you make more than one Product (or family) per Shift,then allocate Available Time by Product/Family — ensuring that total time for the Shift is correct.

The 'Batch' column should usually be left blank except for those (usually rare) Shifts where you make multiple batches of the same Product within a single Shift.

If this never happens in your world... simply hide the entire 'Batch' column.

Rejects

Make a log entry for each batch of Rejects.

For OEE purposes, Rework is just another Category of rejects.

See more complete discussion in the OEE Glossary.

Lost Time Events

Always make a log entry for any event that stops production longer than the 'Downtime Threshold' number of minutes.

Shorter minor stoppages will be reflected in 'Performance Loss'

Import data from each Work Center Log

On each Log sheet...

Filter for the Date range that you want to import to your central OEEData worksheet.

On the OEEData sheet… (which is often in its own workbook)

Generate Analysis sheets

Any values outside of your user-defined 'Andon Tolerances' will be shaded pink, and anything half way close will be shaded yellow— so that you can quickly focus on problems needing attention.

Experiment with Countermeasures to problems that get revealed

Once you have used your powerful OEE software to identify and illustrate your problems...

the next question becomes...

solve

This OEE template comes with an OEE toolkit to solve the problems that you identify

When you own your Systems2win templates, you have the tools that 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...

Wouldn't it be depressing to just be told about all of the problems that you have?

Wouldn't it be more helpful to actually solve the problems that your OEE software identifies?

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SixLosses

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advanced

OEE Excel Template: Advanced Training

Create your own charts

In addition to the many charts in your standard template, you can also optionally add your own, using everything you know about Excel charts.

You can also hide unused charts. Or move them out of the Print Area. Or change the Print Area.

It's Excel. Use everything you know about familiar Microsoft Excel.

Suggestions to keep file sizes manageable

Use separate workbooks to maintain a Daily Log for each Work Center.

Hide or delete unused Analysis sheets

Perhaps start with a copy (or multiple copies) of your workbook to use for generating (temporary) Analysis worksheets.

Save an archive workbook at least every year, or whenever file size becomes slow.

Rather than starting a fresh workbook, perhaps simply delete archived data, leaving some recent history to work with going forward.

Do not exceed 5000 rows of data on any single worksheet.

The Excel 'GoTo' function can fail if there are too many noncontiguous hidden rows.

To import data from Automated Data Collection Devices

Import data to an interim Excel workbook, then write macros in that interim workbook to get the data into a format that matches the Systems2win worksheet where you want to import your data.

You will usually import to a Log sheet, but could also import directly to an OEEData sheet.

Then 'Paste Special > Values' to the next unused data rows.

Home tab > Paste > Paste Special > Values

Note: Custom programming assistance is available at Systems2win's regular hourly billing rate.

OEE Weighting

OEE Weighting only becomes important when aggregating OEE across dissimilar equipment and/or products

which is a highly discouraged bad idea...
because OEE is intended only to measure and improve the effectiveness of the same equipment over time.

It was never intended to serve as a universal accounting standard to compare diverse environments to each other.

But if you feel you must…

then you can personalize your master template with your own User-Defined Calcs on the OEEFilter sheet to apply any weighting system of your choosing.

You cannot change part of an array

If you get this error message, then you are trying to customize something you shouldn't.

You might be trying to delete or move columns that must remain unchanged in order for the Systems2win macros to work.

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paper

Manual Collection of OEE Data

OEE Data Collection Form

Category and Reason Codes

To print a list of your (user-defined) Category and Reason Codes, you can either:

1. Simply Print the DV sheet

   (the codes will be printed on several separate pages)

2. Or you can create your own "cheat sheet"

   Tip: When copying to your custom workbook, use Paste Special > Values

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Glossary

OEE Calculations

and glossary of terms

for TPM Total Productive Maintenance and OEE Overall Equipment Effectiveness

Use CTRL+F to find keywords

Also see Lean Dictionary

OEE Overall Equipment Effectiveness = Availability * Performance * Quality

OEE is calculated by multiplying 3 sub-measures:

1) Availability: % of actual uptime to planned
2) Performance: % of actual throughput to target
3) Quality: % of good units to total

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%

Performance = 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 / Total Units Produced

Total 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 and 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
• Rework

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)

Planned Uptime = Available Time minus Planned Downtime

aka: Planned Production Time, Net Available Time, Scheduled Time, Running Time

It is 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 online training pages)

Loading Effectiveness = Planned Uptime / Available Time

Some companies also measure:

Equipment Utilization = Planned Uptime / Total Possible Available Time (1440 mins per day)

and...

TEEP Total Equipment Effectiveness Performance = OEE * Utilization

Systems2win has chosen not to track Utilization and TEEP in the standard template because:

1. The entire concept of maximizing equipment utilization only fits lean philosophy in the rare situation where customer demand chronically exceeds capacity.
2. 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 Calls)
3. 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 = Max time that work 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.

Change Overs

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.

Standby

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.

Unplanned Downtime

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)

Performance Loss = (1 – OEE Performance Ratio) * Net Operating Time

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 slowdowns 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.

Productive Time = Performance Time – Quality Time Loss

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

 

 

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 further analysis.

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Reading

Suggested Reading for OEE

• Successfully Installing TPM in a Non-Japanese Plant: Total Productive Maintenance, by Edward Hartmann

 

More Suggested Reading

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