The OEE calculation shows how well a machining jig, system, production line or machine is utilising its maximum theoretical capacity and, in particular, how well it is working in comparison to similar equipment. It looks at three key factors: Availability, performance, and quality. Together, these values provide an overall view of the efficiency of a production line.
OEE optimisation has become an important competitive factor. Companies with high OEE values are not only more efficient, but can also react more quickly to market changes and optimise their cost structure.
In this comprehensive article you will find answers to the following questions:
Overall equipment effectiveness was developed to providecompanies with a standardised metric for evaluating their production plants. 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 proportional 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 categorised as "world class" in the industry, as they reflect the effective use of systems, 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 optimised workflows to ensure maximum efficiency.
However, achieving a high OEE value is largely determined by numerous influencing factors that also need to be taken into account. A main aspect is the type of processes and procedures, which affect 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 working with the production system also have an impact on the value.
Calculating the OEE depends on various factors, including
In the following sections, we go into more detail about the practical measures for optimisingthe OEE value.
Availability is one of the most critical factors when calculating the OEE and is significantly influenced by uptime. Planned downtimes, such as maintenance or changeovers, should be optimally planned and minimised. Fastchangeovers and precise format adjustments are key factors for greater flexibility.
Modern systems have adequate technologies that enable format changeovers to be carried out in the shortest possible time, thus significantly reducing planned downtime. The targeted optimisation 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 the overall equipment effectiveness (OEE) describes the percentage of manufactured products that meet the specified requirements (OK) and can be used straightaway without needing any rework. High quality has a direct impact on production efficiency, as it reduces the proportion of rejects and rework, thereby conserving resources and cutting costs.
Innovative concepts and technologies contribute greatly to optimising the quality rate. PWIS-free production plays a central role in coating processes by avoiding contamination and achieving a higher yield. In addition, fail-safe systems are essential, as they can reliably continue production even in the event of unexpected malfunctions.
Implementation of the zero defect principle, which aims to completely eliminate the occurrence of errors from the outset, is an especially forward-looking concept. With modern inspection systems, AI-based process monitoring and automated quality controls a consistently high production yield can be achieved. Maximum transparency by continuously tracking 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.
The precise analysis and optimisation 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 frequently used technologies include MES (Manufacturing Execution System) and SCADA (Supervisory Control and Data Acquisition). These systems continuously record and analyse production data in order to make both technical and organisational problems visible. In addition, cloud-based services offer extended options for storing and evaluating data and monitoring processes using AI.
These factors not only enablecompanies to increase production efficiency, but also to specifically optimise their OEE values.
Material handling, material feed systems, inspection systems, sorting systems and packaging units are integral components of an efficient production system. An optimised 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 optimised both technically and organisationally. 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 minimising errors and rejects.
The digitalised monitoring of automated processes plays a key role in detecting drops in performance at an early stage and initiating specific 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 optimising 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 organisational methods and technologies.