Quality and Stops

Our Machines Are Down Too Much

Downtime is the most visible loss on the floor and often the least measured, whether the asset is a machine, a conveyor or a test stand. Everyone remembers the long breakdown; the short stops never make the report. OEE splits the losses so you can see which one to work first.

What Is Usually Going On

  • Short stops and slow cycles are not recorded, only long breakdowns.
  • Maintenance is fix-on-failure.
  • Basic care (clean, inspect, lubricate) is not done by anyone on a schedule.
  • Changeovers and waiting for material are counted as run time, or not counted.
  • Scrap made at the machine is not tied back to its OEE.

How to Fix It

  1. Measure OEE in partsOEE = availability x performance x quality. Calculate each one, not just the total.
  2. Log stops by causeA tally at the machine by reason and minutes, every shift, for at least two weeks.
  3. Pareto the hoursRank causes by lost hours. Work the top one or two.
  4. Fix the top causeBreakdowns: root cause and PM. Short stops: jams and sensors at the machine. Setups: SMED. Slow cycles: programs and feeds against standard.
  5. Start autonomous maintenanceOperators clean, inspect and lubricate on a checklist. Cleaning is inspection.
  6. Start with the constraintAn hour gained on the constraint machine is an hour of output. An hour gained elsewhere may only become idle time.

Start Free

Guides and web tools on this site. No account needed.

Guide
OEE (Overall Equipment Effectiveness)
Guide
Downtime Analysis & Categorization
Guide
Total Productive Maintenance (TPM)
Calculator
OEE Calculator
Template
5 Whys Template

When It Moves to the Floor

The same work as an offline file you keep: saved scenarios, print and export, no internet needed on the floor.

Common Questions

What is a good OEE?

One that is higher than last month on your constraint. Published benchmarks rarely count losses the way your plant does. Compare a machine to itself.

Does OEE include planned downtime?

Standard OEE uses planned production time, so planned stops like breaks are out. Write the rule down and apply it the same way on every machine.

Which machine should we start on?

The constraint. Its losses cost output. Other machines have spare time to absorb some loss.

What is TPM?

Total productive maintenance: operators take on basic care, maintenance moves to planned and predictive work, and both work the losses together.