Factory OEE Navigator

Phase 1 — Preparation & Foundation

SETUP

🏭 Factory Information

Factory / Production Area Name

Product / Industry

Working Days / Month

Shifts / Day

Hours / Shift

Planned Breaks / Shift (min)

Meetings / Handover (min)

Operational Situation (Kennedy, 2018)

🔧 Production Lines & Machines

⚡ Speed Definitions — Do NOT confuse Ideal Speed with Standard Speed

📖

rule: Ideal Speed = OEM design speed or best 5-min sample speed. Standard Speed (for scheduling/costing) is typically 10–20% lower. Using Standard Speed instead of Ideal Speed causes overinflated OEE results.

📥 Import / Export Setup & Data from Excel

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4 Sheets: (1) Factory Info — name, product, shifts, hours, breaks. (2) Lines & Machines — Line ID, Line Name, Line Type, Machine ID, Machine Name, Machine Type, Ideal Speed, Std Speed. (3) OEE Data — per-machine loss & output data. (4) Root Cause Analysis — 5-Why entries per machine. Download the template, fill it in, and upload to auto-populate everything.

📂 Choose Excel File No file selected

🎯 OEE Objectives & Targets

Current OEE Baseline (%)

12-Month Target (%)

3-Year Ideal Vision (%)

Improvement Goals

Phase 2 & 3 — Data Collection & Measurement

MEASURE

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Three Data Sources: (1) High-Level OEE: Good Output ÷ (Available Time × Ideal Speed) — most accurate but no detail. (2) Continuous Recording from production sheets. (3) Observations (4–5 hrs) to capture minor unrecorded stoppages. Use all three. All times in minutes.

Phase 3 — OEE Results (Time Loss Model + HLOEE)

RESULTS

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Two calculation methods: HLOEE = Good Output ÷ (Available Time × Ideal Speed) — simple & accurate but no loss detail. Time Loss Model = Value Adding Time ÷ Available Time — shows all 7 loss categories. Both should give the same answer.

📋 Machine-Level OEE — 7 Losses Model

Machine	Line	Availability	Performance	Quality	OEE (Time Loss)	HLOEE ✓	Status	Bottleneck

📊 Production Efficiency (PE)

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Kennedy: PE removes Planned Downtime & Setup losses — used for cross-line comparison. OEE should never be benchmarked between sites; PE can be used with caution.

🏭 TEEP — Total Effective Equipment Performance

Phase 4 — 7 Losses Analysis (Kennedy Model)

ANALYZE

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7 Losses (expanded from Nakajima's 6): Planned Downtime is added as a separate Availability loss. Address losses from BOTH ends of the Pareto: Technical issues via Cross-functional Teams (deductive); People Development issues via Area-Based Teams (inductive).

📊 7 Losses — Time Lost (min/month)

📈 Pareto Analysis

🏆 Loss Priority Ranking — Technical vs People Development Classification

Phase 4 — Root Cause Analysis

RCA

🌿 5-Why Analysis

Problem Statement

Issue Classification (Kennedy)

Root Cause

🐟 Fishbone (Ishikawa)

Problem Effect

📋 RCA Log

No RCA entries yet.

OEE Improvement Vision (Kennedy Loss Analysis)

VISION

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For each of the 7 Losses, define an As-Is, 12-Month Vision, and 3-Year Ideal Vision with documented assumptions. Typically 50% of the Ideal Vision is achieved in Year 1 (low-hanging fruit), remaining 50% over Years 2–3. Use Zero-Based thinking — forget past targets, focus on perfect performance.

📊 OEE Improvement Visions Sheet — 7 Losses

Loss Category	OEE Factor	As-Is (%)	12-Month Vision (%)	3-Year Ideal Vision (%)	Gap	Assumptions / Reasons	Issue Type

⚖️ Gap Opportunity Analysis — Technical vs People Development (Kennedy)

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Typically ~50% of OEE loss gap is Technical (Cross-functional Teams) and ~50% is People Development (Area-Based Teams). If obvious Technical issues are already fixed, People Development share is higher.

Phase 5 & 6 — Improvement & Control

IMPROVE

🎯 Improvement Action Register

#	Action	Loss Targeted	Team Type	Expected Gain	Priority	Owner	Due	Status

📈 Projected OEE

Add actions and click Calculate.

📊 OEE Comparison

🔒 Control & Sustain — 3-Level Review

📅 DAILY (Frontline Leader)

✅ Monitor OEE at least hourly
✅ 10-min stand-up review
✅ Record all 7 loss events
✅ Update OEE run chart
✅ Ask "why" while fresh in memory

📆 WEEKLY (Line Manager)

✅ HLOEE weekly run chart
✅ Pareto chart update
✅ PM checklist compliance
✅ Production Area Based Team activity
✅ CI improvement time (WAM/5S)

📊 ANNUALLY (CI Team)

✅ Full OEE Loss Analysis refresh
✅ Update Ideal Vision targets
✅ New 12-month plan
✅ Evaluate gap closure rate
✅ Launch next improvement cycle

OEE Improvement Rating — 10 Requirements (Kennedy Appendix)

ASSESS

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Score each requirement 0–5. 0=No evidence, 1=Attempted/10%, 2=Some evidence/25%, 3=Halfway/50%, 4=Close to full/75%, 5=Fully implemented/100%. Score below 50% = significant improvement opportunity.

📊 Rating Summary

📈 Score Chart

Factory OEE Dashboard

LIVE

📊 Machine OEE vs World Class

🔍 7 Losses Distribution

🏭 Production Line Status

🏆 Best Practice Benchmark (Kennedy, 2018)

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Kennedy warning: "These numbers can be quite ridiculous at many sites." Best practice OEE should be based on actual business requirements for each line — not a fixed 85% target.

Metric	World Class (Discrete Mfg)	Continuous Process	Your Factory	Gap	Status

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