a5c-ai OEE Calculator
Overview
The OEE Calculator skill provides comprehensive capabilities for calculating and analyzing Overall Equipment Effectiveness. It supports availability, performance, and quality tracking, six big loss categorization, and world-class benchmarking.
Capabilities
- Availability calculation
- Performance rate tracking
- Quality rate measurement
- OEE trending and dashboards
- Six big loss categorization
- Pareto of losses
- Improvement target setting
- World-class benchmarking
Used By Processes
- LEAN-001: Value Stream Mapping
- SIX-002: Statistical Process Control Implementation
- CI-003: Benchmarking Program
Tools and Libraries
- MES integration
- OEE software
- Real-time dashboards
- Data collection systems
Usage
skill: oee-calculator
inputs:
equipment: "CNC Machine 5"
period: "2026-01-15"
shift_data:
planned_production_time: 480 # minutes
downtime:
- type: "breakdown"
minutes: 30
- type: "changeover"
minutes: 20
ideal_cycle_time: 0.5 # minutes per unit
total_count: 800 # units
good_count: 780 # units
outputs:
- oee_score
- availability
- performance
- quality
- loss_breakdown
- improvement_opportunities
- trend_analysis
OEE Calculation
Formula
OEE = Availability x Performance x Quality
Where:
Availability = Run Time / Planned Production Time
Performance = (Total Count x Ideal Cycle Time) / Run Time
Quality = Good Count / Total Count
Example Calculation
Planned Production Time: 480 minutes
Downtime: 50 minutes
Run Time: 430 minutes
Ideal Cycle Time: 0.5 minutes
Total Count: 800 units
Good Count: 780 units
Availability = 430 / 480 = 89.6%
Performance = (800 x 0.5) / 430 = 93.0%
Quality = 780 / 800 = 97.5%
OEE = 89.6% x 93.0% x 97.5% = 81.3%
Six Big Losses
| Loss Category | OEE Factor | Examples |
|---|---|---|
| Breakdowns | Availability | Equipment failures |
| Setup/Adjustments | Availability | Changeovers, warm-up |
| Small Stops | Performance | Jams, minor issues |
| Reduced Speed | Performance | Running below ideal rate |
| Startup Rejects | Quality | Scrap during start-up |
| Production Rejects | Quality | In-process defects |
OEE Benchmarks
| OEE Level | Classification | Typical Range |
|---|---|---|
| World Class | Best in class | 85%+ |
| Good | Above average | 70-85% |
| Average | Typical | 60-70% |
| Low | Needs improvement | 40-60% |
| Poor | Significant issues | <40% |
World-Class Targets
| Factor | World Class | Typical |
|---|---|---|
| Availability | >90% | 85% |
| Performance | >95% | 90% |
| Quality | >99.9% | 98% |
| OEE | >85% | 60% |
Loss Analysis Process
- Collect accurate loss data
- Categorize by six big losses
- Create Pareto chart
- Focus on top losses
- Apply appropriate methodology
- Track improvement
Integration Points
- Manufacturing Execution Systems
- PLC/SCADA systems
- Quality Management Systems
- Maintenance management (CMMS)