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Boost operational efficiency and profit with OEE tracking powered by Caddis Systems.
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Overall Equipment Effectiveness (OEE) is a key performance indicator (KPI) that measures manufacturing productivity. It provides a comprehensive picture of how well a manufacturing operation is running by combining three critical factors into a single score.
In essence, OEE answers the question: "How close are you to producing only good parts, as fast as possible, with no stop time?" An OEE score of 100% represents perfect production.
OEE is calculated from three underlying components, each representing a different type of production loss. Understanding these components is crucial for identifying areas for improvement.
1. Availability
Availability accounts for any time the process is stopped for a significant period. These are often called downtime losses and include both unplanned stops (like equipment failures and material shortages) and planned stops (like changeovers).
The formula for Availabilityi:
Availability = Run Time / Planned Production Time
Where Run Time is the planned production time minus any stop time.
2. Performance
Performance accounts for any factors that cause the process to operate at less than its maximum possible speed. These are known as speed losses and include slow cycles or minor stops that aren't tracked as downtime.
The formula for Performance is:
Performance = (Ideal Cycle Time × Total Count) / Run Time
Where Ideal Cycle Time is the fastest possible time to manufacture one part.
3. Quality
Quality considers any parts produced that do not meet quality standards, including parts that need to be reworked. These are quality losses. The goal is to produce only good parts the first time.
The formula for Quality is:
Quality= Good Count / Total Count
Where Good Count is the number of units produced that meet standards without rework.
Calculating OEE involves multiplying the three component scores together. This single percentage provides a snapshot of overall operational efficiency.
The formula for OEE is: OEE= Availability × Performance × Quality
Calculation Example
Let's consider a single 8-hour (480-minute) shift with the following data:
Planned Production Time: 480 minutes
Downtime (unplanned): 60 minutes
Ideal Cycle Time: 1 minute per piece
Total Pieces Produced: 350
Defective Pieces: 15
First, we calculate each component:
Availability:
Run Time = 480 min - 60 min = 420 minutes
Availability = 420 min / 480 min = 0.875 or 87.5%
Performance:
Performance = (1 minute/piece * 350) / 420 min = 0.833 or 83.3%
Quality:
Good Count = 350 pieces - 15 pieces = 335 pieces
Quality= 350 total pieces/335 good pieces ≈ 0.957 or 95.7%
Finally, we calculate the overall OEE score:
OEE=0.875 × 0.833 × 0.957 ≈ 0.698 or 69.8%
OEE is a powerful tool for modern manufacturing because it provides deep insights into the production process and drives continuous improvement. Its importance stems from several key benefits:
Identifies Loss: OEE's greatest strength is highlighting the "Six Big Losses" in manufacturing (e.g., equipment failure, setup and adjustments, reduced speed, defects). By breaking down performance into Availability, Performance, and Quality, teams can pinpoint exactly where and why production is falling short.
Maximizes Asset Utilization: By focusing on improving OEE, companies can increase their output using existing equipment. This means they can boost production capacity and profitability without significant capital investment in new machinery.
Enhances Competitiveness: Higher OEE leads to lower manufacturing costs, better product quality, and more reliable delivery times. This combination makes a company more competitive in the marketplace.
Provides a Standardized Benchmark: OEE offers a standardized metric that can be used to compare the performance of different machines, shifts, teams, or even entire plants. This allows for data-driven decision-making and the sharing of best practices across an organization.
Caddis Systems provides your team with real-time machine insights and expert guides to reduce unplanned downtime and increase productivity.
Monitor machine health and performance in real time through continuous tracking of critical metrics — including downtime, utilization, OEE, cycle time, changeover time, and condition data.
Log and timestamp machine downtime events to generate comprehensive reports. Identify the root causes of downtime and develop strategies to minimize disruptions and enhance productivity.
Schedule maintenance tasks proactively to minimize unexpected downtime and extend the lifespan of your machines.
Receive instant notifications via text or email based on live machine data. Act swiftly to avert prolonged downtime, reduce repair expenses, and ensure seamless operations.
Most machine monitoring tools hand you a dashboard and walk away. Caddis comes loaded with battle-tested playbooks — built from years on our own factory floor — so your team knows what to do with the data from day one
Explore Playbooks
Shift from reactive to proactive. Schedule maintenance by actual runtime and cycle counts — not guesswork — so you catch problems before they become expensive emergencies.
Pinpoint your top three downtime causes in the first week. Then systematically eliminate them using a proven root-cause framework your whole team can follow — no analyst required.
Uncover hidden capacity that's already sitting in your shop. Identify idle patterns by shift, operator, and machine — then close the gap with targeted scheduling adjustments.
Move your OEE score from a vanity metric to an action plan. Track availability, performance, and quality together — then follow a weekly cadence to drive measurable gains each month.
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Caddis devices can be installed same day with no disruptions. No I.T. Team required.
Plug Caddis devices into your machines — works with virtually any legacy or modern equipment. Most shops are up and running in under 2 hours.
View real-time machine insights to benchmark performance and identify downtime reasons.
Use pre-built reports, dashboards and expert guides to make reduce unplanned downtime and improve productivity.
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See how Caddis can provide real-time machine insights and expert guides to help improve your plant operations on Day 1.
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