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Calculating OEE totals - General example

Worked example of how Availability, Performance, Quality and OEE are calculated per station, per station group, per department and for the whole company, and why the total OEE can be lower than individual values.

On this page
  1. OEE values calculated by stations
  2. Availability
  3. Performance
  4. Quality
  5. OEE
  6. OEE values calculated by station groups
  7. Example for Group 6
  8. OEE values calculated by departments
  9. OEE values calculated for the whole company
  10. Why is the total OEE lower than the individual OEE values?
  11. How to detect this?
  12. Where can I adjust the speed settings?
  13. A simplified example of how such total OEE value can occur and is calculated

OEE values calculated by stations

As this is the base for all the next calculations, we first break it down on a station level.

Availability

Station name Good production Speed loss Production time Planned Time Availability
Line A 1303697 96439 1400136 1584254 88.38%
Line B 1350052 90773 1461912 1728000 84.60%
Line C 459990 86884 546874 623970 87.64%
Line D 1350052 90733 1440825 1843200 78.17%
Line E 680803 120517 801320 917991 87.29%
Line F 893506 174142 1067648 1680471 63.53%
Line G 278304 57147 335451 624505 53.72%
Line H 447802 213366 661168 1193091 55.41%
Line I 91682 11874 103556 405158 25.56%
Total 6901117 917776 7818890 10600640 73.76%

Performance

Station name Produced qty Ideal produced qty Performance
Line A 3268496.4 3542344.08 92.27%
Line B 3911907 4086207.76 95.73%
Line C 1678000 1822913.33 92.05%
Line D 2197145 2213895.83 99.24%
Line E 2180700 2558881.85 85.22%
Line F 2215470 2689550.56 82.37%
Line G 1372000 1582210.54 86.71%
Line H 3080175 4595117.6 67.03%
Line I 222510 239259.66 93.00%
Total 20126403.4 23330381.21 86.27%

Quality

Station name Good quantity Scrap Total qty Quality
Line A 3268496.4 0 3268496.4 100%
Line B 3911907 0 3911907 100%
Line C 1678000 0 1678000 100%
Line D 2197145 0 2197145 100%
Line E 2180700 0 2180700 100%
Line F 2215470 0 2215470 100%
Line G 1372000 0 1372000 100%
Line H 3080175 0 3080175 100%
Line I 222510 0 222510 100%
Total 20126403.4 0 20126403.4 100%

OEE

Station name Availability Performance Scrap OEE
Line A 88.38% 92.27% 0 81.55%
Line B 84.60% 95.73% 0 80.99%
Line C 87.64% 92.05% 0 80.68%
Line D 78.17% 99.24% 0 77.58%
Line E 87.29% 85.22% 0 74.39%
Line F 63.53% 82.37% 0 52.33%
Line G 53.71% 86.71% 0 46.58%
Line H 55.42% 67.03% 0 37.15%
Line I 25.56% 93.00% 0 23.77%
Total 73.76% 86.27% 0 63.63%

OEE values calculated by station groups

For station groups we sum up all the same values and use same formulas.

Station name Good production Speed loss Production time Planned Time Availability Produced qty ideal produced qty
Line D 1350052 90773 1440825 1843200 78.17% 2197145 2213895.83
Group 1 1350052 90773 1440825 1843200 78.17% 2197145 2213895.83
Line F 893506 174142 1067648 1680471 63.53% 2215470 2689550.56
Line I 91682 11874 103556 405158 25.56% 222510 239259.66
Group 2 985188 186016 1171204 2085629 56.16% 2437980 2928810.22
Line A 1303697 96439 1400136 1584254 88.38% 3268496.4 3542344.08
Group 3 1303697 96439 1400136 1584254 88.38% 3268496.4 3542344.08
Line C 459990 86884 546874 623970 87.64% 1678000 1822913.33
Line E 680803 120517 801320 917991 87.29% 2180700 2558881.85
Group 4 1140793 207401 1348194 1541961 87.43% 3858700 4381795.18
Line B 1395281 66634 1461915 1728000 84.60% 3911907 4086207.76
Group 5 1395281 66634 1461915 1728000 84.60% 3911907 4086207.76
Line G 278304 57147 335451 624505 53.71% 1372000 1582210.54
Line H 447802 213366 661168 1193091 55.42% 3080175 4595117.6
Group 6 726106 270513 996619 1817596 54.83% 4452175 6177328.14
Total 6901117 917776 7818893 10600640 73.76% 20126403.4 23330381.21

Example for Group 6

OEE values calculated by departments

As for station groups, it would be the same, summing up values in a department

Station name Good production Speed loss Production time Planned Time Availability Produced qty ideal produced qty
Line D 1350052 90773 1440825 1843200 78.17% 2197145 2213895.83
Line F 893506 174142 1067648 1680471 63.53% 2215470 2689550.56
Line I 91682 11874 103556 405158 25.56% 222510 239259.66
Department 1 2335240 276789 2612029 3928829 66.48% 4635125 5142706.05
Line A 1303697 96439 1400136 1584254 88.38% 3268496.4 3542344.08
Line C 459990 86884 546874 623970 87.64% 1678000 1822913.33
Line E 680803 120517 801320 917991 87.29% 2180700 2558881.85
Department 2 2444490 303840 2748330 3126215 87.91% 7127196.4 7924139.26
Line B 1395281 66634 1461915 1728000 84.60% 3911907 4086207.76
Line G 278304 57147 335451 624505 53.71% 1372000 1582210.54
Line H 447802 213366 661168 1193091 55.42% 3080175 4595117.6
Department 3 2121387 337147 2458534 3545596 69.34% 8364082 10263535.9
Company total 6901117 917776 7818893 10600640 73.76% 20126403.4 23330381.21

OEE values calculated for the whole company

We take the sum of all stations and sum it up. The values are seen in each table above.

Why is the total OEE lower than the individual OEE values?

This comes from incorrect speed settings for products - one or more product has the actual production speed that exceeds the set ideal speed and causes performance value to go over 100%.

How to detect this?

  • Shift View:
    • OEE and speed widgets.
    • Hourly produced quantity vs target (based on the ideal speed).
  • Reports:
    • Quantity report (ideal qty vs total qty), OEE report (performance value).
  • Factory Overview:
    • Performance indicator from the filter options.
  • Dashboard:
    • Different widgets allow tracking quantities (against a target) and also performance.

According to OEE theory, this can not happen. This means that the product speed settings for any station (called "routes" in Evocon) need to be checked and corrected. If performance is up to 100% and not over, then the total OEE would also fall somewhere between the individual values.

Where can I adjust the speed settings?

  • Under product details in Settings, more information here.

A simplified example of how such total OEE value can occur and is calculated

  • Let's say these are OEE report results for 3 stations over 6 months:

    Screenshot: Let's say these are OEE report results for 3 stations over 6 months:

  • We can see that the total OEE is lower than any of the individual OEE value for this period.

  • If we calculate each station separately, we get the results as above:

    • Station 1
      • Availability 25,37%
      • Performance 279,71%
      • Quality 95,50%
      • OEE = Availability × Performance × Quality = 67,77%
    • Station 2
      • Availability 20,67%
      • Performance 297,82%
      • Quality 96,63%

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