The OEE calculation shows how well a machining jig, machine, production line, or system is utilizing its maximum theoretical capacity and, in particular, how well it is working in comparison to parallel equipment. It looks at three key factors: availability, performance, and quality. Together, these values provide a complete overview of the efficiency of a production line.
OEE optimization has become a decisive competitive factor. Companies with high OEE values are not only more efficient, but can also react more quickly to market changes, and optimize their cost structure.
In this comprehensive article, you will find answers to the following questions:
The overall equipment effectiveness was developed to provide companies with a standardized metric for evaluating their production facilities. It makes it possible to compare the actual productivity of a machine or system with its maximum possible capacity.
The OEE assessment is based on three central factors: Availability, performance, and quality (uptime, throughput, yield). This percentage key figure provides a comprehensive perspective on the effectiveness and efficiency of a production unit.
Time availability:
Productive performance:
Quality of the production result:
The OEE is calculated using this formula:
But what is a good OEE value? An OEE value that can be described as very good is typically 80% or higher for discrete production processes. Such values are generally classified as "world class" in the industry, as they reflect the effective use of equipment, high productivity, and an optimum combination of availability, performance, and quality. Companies that achieve such top results usually have highly developed production systems, and use state-of-the-art technologies and optimized workflows to ensure maximum efficiency.
However, achieving a high OEE value is largely determined by a multitude of influencing factors that ultimately need to be taken into account. A central aspect is the form of the process and procedure, which affects both the structure of the production processes and the efficiency of the methods used. System maturity, system runtime (age) and good cooperation between those involved in the production system also have an impact on the value.
The OEE calculation depends on various factors, including:
In the following sections, we go into more detail about the practical measures for optimizing the OEE value.
Availability is one of the most critical factors in the OEE calculation, and is significantly influenced by uptime. Planned downtimes, such as for maintenance or retooling, should be optimally planned and reduced to a minimum. Quick changeovers and precise format adjustments are the decisive levers for greater flexibility.
Modern systems have adequate technologies that enable format changes to be carried out in the shortest possible time, which significantly reduces planned downtimes. The targeted optimizations of set-up times using methods such as SMED (single-minute exchange of die) also help to further reduce changeover times and significantly increase machine availability.
The quality factor within overall equipment effectiveness (OEE) describes the percentage of manufactured products that meet the specified requirements (OK) and can be reused directly without reworking. High quality has a direct impact on production efficiency, as it reduces the proportion of rejects and rework, which conserves resources and reduces costs.
Innovative concepts and technologies contribute significantly to optimizing the quality rate. Production without paint wetting impairment substances (PWIS) plays a central role in coating processes in order to avoid contamination and achieve a higher yield. In addition, fail-safe systems are essential, as they can reliably continue production even in the event of unexpected disruptions.
The implementation of the zero defect principle, which aims to completely eliminate the occurrence of defects from the outset, is particularly forward-looking. The use of modern inspection systems, AI-based process monitoring, and automated quality controls ensures a consistently high production yield. Maximum transparency through the seamless tracking of correctly executed production processes also contributes to the zero-defect rate.
Performance is another key efficiency factor of overall equipment effectiveness (OEE), and assesses how smoothly production runs in relation to the maximum possible capacity. It has a direct impact on throughput and the overall effectiveness of a production line.
Precise analysis and optimizations of performance require the use of modern software tools that enable detailed monitoring. Such tools identify delays, inefficiencies, and potential bottlenecks in real time, allowing companies to react quickly to deviations.
The most commonly used technologies include MES (manufacturing execution system) and SCADA (supervisory control and data acquisition). These systems continuously record and analyze production data in order to make both technical and organizational problems visible. In addition, cloud-based services offer extended options for data storage, analysis, and the implementation of AI-supported process monitoring.
These factors not only enable companies to increase production efficiency, but also to optimize their OEE values in a targeted manner.
Material handling, material feed systems, inspection systems, sorting systems and packaging units are integral components of an efficient production system. An optimum end-of-arm (EOA) solution can improve the efficiency of handling systems, and thus increase the performance of the line.
A high OEE value is based on how effectively the availability, performance, and quality of a system are optimized, both technically and organizationally. Fast changeovers and precise format adjustments make a decisive contribution to increasing availability. At the same time, clearly defined and fail-safe production methods increase quality by minimizing errors and rejects.
The digitalized monitoring of automated processes plays a key role in detecting drops in performance at an early stage, and initiating targeted countermeasures. In particular, the use of modern end effectors and other automated handling solutions for production logistics processes significantly increases the overall performance of a production line by avoiding bottlenecks and optimizing the material flow.
The interaction of all these elements enables companies to improve their overall equipment effectiveness (OEE) in the medium to long term and achieve a benchmark value that is regarded as the measure of excellent production efficiency. The key to success lies in continuous improvement, the detailed analysis of production systems, and the optimal use of modern organizational methods and technologies.