Short answer
OEE calculator
Type your shift’s numbers. The defaults are the worked example below. (The calculator also has its own page, with the formulas and OEE vs TEEP vs OPE.)
Your OEE
71.3%
Typical for a shop that measures. The gap to 85% is the hidden factory.
- Availability
- 86.2%
- 388 of 450 min running
- Performance
- 84.5%
- 410 of 485 possible pcs
- Quality
- 97.8%
- 401 of 410 good
Downtime alone cost about 77 pieces this shift at the ideal cycle.
The five numbers you need from the floor
Inputs
- Planned production time
- Shift length minus planned breaks (min)
- Downtime
- Every unplanned stop: setup, breakdown, tooling, waiting (min)
- Ideal cycle time
- Fastest repeatable time per piece (sec) — from the part master
- Total pieces
- Good and rejected, counted at the machine
- Rejected pieces
- Scrap and rework
Step by step
- 01
Availability
Run time = planned time − downtime. Availability = run time ÷ planned time.
450 − 62 = 388 min. 388 ÷ 450 = 86.2%. - 02
Performance
Ideal output = run time ÷ ideal cycle. Performance = actual ÷ ideal.
388 × 60 ÷ 48 = 485 pcs possible; 410 ÷ 485 = 84.5%. - 03
Quality
Good pieces ÷ total pieces.
(410 − 9) ÷ 410 = 97.8%. OEE = 0.8622 × 0.8454 × 0.9780 = 71.3%.
What is a good OEE?
The benchmark most people quote comes from OEE.com: 85% is considered world-class for discrete manufacturing — a figure that goes back to Seiichi Nakajima’s TPM work in Japan — while most manufacturers are closer to 60%, and more plants score below 45% than above 85%. World-class OEE is usually broken down as roughly 90% availability, 95% performance and 99%+ quality.
Job shops sit lower than high-volume lines by nature — more setups, more part changes — so compare a machine with itself over time, not with a benchmark from a bottling plant. The useful question is not “is 71% good?” but “which of the three factors is costing the most, and what is the biggest reason inside it?”
Four mistakes that make OEE look better than it is
| Mistake | What it does | Do this instead |
|---|---|---|
| Using average cycle time as the ideal | Performance reads ~100% by definition | Use the part master's ideal cycle or a timed best run |
| Not logging stops under 10 minutes | Availability is inflated; the loss hides in performance | Log every stop at the moment, one tap, with a reason |
| Counting setup as run time | Availability looks fine; setups never get shorter | Setup is downtime; track it separately too |
| Counting rejects at inspection, not at the machine | Quality is right, but the cause and the time are lost | Log rejects at the machine with a reason |
OEE per job, not just per machine
A machine’s OEE mixes every part it ran. The number that changes quoting is OEE per part: which components run near their ideal cycle with few rejects, and which ones quietly lose money on every batch. You get that only when each piece, stop and reject is attached to a job card — the reason production tracking and OEE belong on the same screen.
Skip the spreadsheet. See your real OEE by the end of the first shift.
A 20-minute demo, on-site in Rajkot and across Gujarat or over a call anywhere in India. Free 15-day trial, no hardware to buy from us.
Questions shop owners ask
What is the OEE formula?
+
OEE = Availability × Performance × Quality. Availability = run time ÷ planned production time. Performance = (ideal cycle time × total pieces) ÷ run time. Quality = good pieces ÷ total pieces. Multiply the three as decimals; the result is your OEE as a percentage.
What counts as planned production time?
+
The shift length minus planned breaks — tea, lunch, planned maintenance, and any time the machine was not scheduled to run. Everything else that stopped the machine is downtime and counts against availability.
Where do I get the ideal cycle time?
+
From the part master or a timed run of the fastest repeatable cycle — the time the process allows, not the average you usually get. Using the average instead of the ideal is the most common way OEE gets flattered.
Is setup time downtime?
+
Yes — in standard OEE, changeover and setup count as availability loss because the machine is not producing. Many job shops track setup separately as well, because it is the loss they can do most about.
Should rework count as a reject?
+
Yes. Quality counts pieces that were right the first time. A reworked piece was not, so it is a quality loss even if it eventually ships.
What is the difference between OEE and OPE?
+
OEE measures one machine against its own ideal during planned production time. OPE — overall process (or production) effectiveness — widens the view to the whole process, including manual steps, people and often planned stops, so it usually reads lower. Definitions of OPE vary between companies, so write down which losses yours includes before comparing numbers.
Can OEE be more than 100%?
+
No. An OEE above 100% means one of the inputs is wrong — usually an ideal cycle time slower than the machine really runs, or pieces counted twice.
How is OEE different from utilisation?
+
Utilisation asks how much of the calendar the machine ran. OEE asks how well it produced when it was planned to run, including speed and quality. A machine can have high utilisation and poor OEE — running all day at half speed, making scrap.
Related
- OEE calculatorFive numbers from one shift in, OEE and its three factors out. No sign-up.
- OEE softwareAvailability × performance × quality, computed from real floor events.
- Downtime reason codes27 reasons in 8 groups, worded for one-tap logging at the machine.
- Daily production report formatFree Excel and printable templates, a worked example and every formula.