Six Big Losses in OEE (Overall Equipment Effectiveness)

 

The Six Big Losses in OEE (Overall Equipment Effectiveness) :

1. Unplanned Stops
2. Planned Stops
3. Small Stops
4. Slow Cycles
5. Production Defects
6. Startup Defects

Unplanned Stops:

Unplanned Stops are significant periods of time in which equipment is scheduled for production but is not running due to an unplanned event. Examples include equipment breakdowns, tool failures, unplanned maintenance, lack of operators or materials, being starved by upstream equipment or being blocked by downstream equipment.

Planned Stops:

Planned Stops are periods of time in which the equipment is scheduled for production but is not running due to a planned event. Examples include changeovers, tooling adjustments, cleaning, planned maintenance, and quality inspections. Many companies also categorize breaks and meetings as Planned Stops.

Small Stops:

Small Stops occur when equipment stops for a short period of time (typically a minute or two) with the stop resolved by the operator. Small Stops are often chronic (same problem/different day), which can

make operators somewhat blind to their impact. Examples include misfeeds, material jams, incorrect settings, misaligned or blocked sensors, equipment design issues, and periodic quick cleaning.

Slow Cycles:

Slow Cycles occur when equipment runs slower than the Ideal Cycle Time (the theoretical fastest possible time to manufacture one piece). Examples include dirty or worn out equipment, poor lubrication, substandard materials, poor environmental conditions, operator inexperience, startup, and shutdown.

Production Defects:

Production Defects are defective parts produced during stable (steadystate) production. This includes parts that can be reworked, since OEE measures quality from a First Pass Yield perspective. Examples include incorrect equipment settings, operator or equipment handling errors or lot expiration.

Startup Defects:

Startup Defects are defective parts produced from startup until stable production is reached. They can occur after any equipment startup, however, are most commonly tracked after changeovers. Examples include sub optimal changeovers, equipment that needs “warm up” cycles, or equipment that inherently creates waste after startup.

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