OEE, downtime and scrap: production losses by the numbers

Skills you'll practise

• Calculate planned production time, run time, availability, performance, quality and OEE from shift data, stating each denominator
• Classify a production loss as an availability, performance or quality loss
• Record downtime, scrap and rework with specific, honest reason codes and times
• Calculate scrap and rework rates against a stated denominator
• Build and read a Pareto of losses and choose where to investigate first
• Explain why OEE figures can't be compared across lines or weeks unless the definitions match

Course outline

1. 1.OEE, downtime and scrapVideo · 2 min
2. 2.What OEE measuresLesson · 18 min
3. 3.Sorting losses: the six big lossesLesson · 17 min
4. 4.Recording downtime and scrap honestlyLesson · 20 min
5. 5.OEE, downtime and scrap: production losses by the numbers: knowledge checkKnowledge check · 20 questions
6. 6.OEE, downtime and scrap: production losses by the numbers: practical exerciseKnowledge check · 1 question
7. 7.Final exam8 questions · passing it completes the course, so people who already know the material can test out

Sources it draws on

The lessons and questions are written from these references, so learners can go back to the original.

• OEE.com (Vorne Industries): Calculating OEE (planned production time, run time, ideal cycle time, good count; availability, performance, quality)
• OEE.com (Vorne Industries): The six big losses in manufacturing
• General quality practice: Pareto analysis (sort categories largest first, add a cumulative line)
• Your site's quality manual, control plans, drawings, work instructions and procedures (these govern)