OEE Calculator Template

The OEE calculator template provides automated calculations from simple input data. The **Data Entry** section captures: planned production time (shift duration minus scheduled breaks and maintenance), actual run time (planned time minus unplanned downtime), ideal cycle time (the fastest achievable cycle time for the product), total units produced, and good units produced. The template automatically calculates the three OEE components: **Availability** = Run Time / Planned Production Time, **Performance** = (Ideal Cycle Time × Total Count) / Run Time, **Quality** = Good Count / Total Count, and **OEE** = Availability × Performance × Quality. A **Loss Waterfall** chart visually breaks down the gap between 100% OEE and actual OEE, showing exactly how many hours are lost to each category: unplanned downtime (availability loss), speed loss (performance loss), and defects (quality loss). Trend charts track OEE and its components over time. A Six Big Losses Pareto chart identifies the top loss categories for focused improvement.

Each shift or day, enter the five raw data points: planned production time, actual run time, ideal cycle time for the product(s) run, total units produced, and good units produced (units passing quality inspection without rework). The template handles all calculations automatically. Review the results at the daily production meeting, focusing on the largest loss category: Is downtime the biggest issue (focus on TPM and maintenance improvement)? Is speed loss dominant (investigate reduced speed causes — worn tooling, incorrect settings, minor stops)? Is quality the main problem (focus on defect root cause analysis)? Over time, the trend charts reveal whether improvement efforts are working. Compare OEE across shifts and operators to identify best practices that can be shared. Set progressive targets: if current OEE is 55%, target 65% in three months rather than jumping to world-class 85%. Pair OEE tracking with your production schedule in LinePlanner to use actual OEE data for realistic capacity planning rather than theoretical equipment ratings.

OEE scores require context for meaningful interpretation. An OEE of 85% is considered world-class for discrete manufacturing but may be typical for continuous process industries. The global average for discrete manufacturing is approximately 60%, meaning 40% of productive potential is lost. More important than the absolute OEE number is the breakdown: a factory with 90% Availability, 80% Performance, and 70% Quality (OEE = 50.4%) has a very different improvement path than one with 70% Availability, 90% Performance, and 90% Quality (OEE = 56.7%) — even though the second factory has higher OEE, the first factory's quality problem may be more expensive to tolerate. Always trend OEE over time rather than reacting to single-day scores, which can be skewed by unusual events. Stratify OEE by product, because changeovers between dissimilar products reduce OEE significantly. Do not compare OEE across fundamentally different equipment types — a CNC machine and an injection molder have different loss profiles. Instead, compare each machine against its own historical trend.