Guide hub
OEE
Overall Equipment Effectiveness multiplies availability, performance, and quality into one number describing how much of a machine's possible output it actually produced. The guides below cover the calculation itself, what other shops run as a benchmark, the common ways OEE gets inflated, and how it relates to TEEP, utilization, and the six big losses framework.
29 guides
- 01 First Pass Yield vs Scrap Rate: The Difference That Hides Rework Two quality numbers that look similar and answer different questions. What rework hides from a scrap rate, and what each one leaves out on its own. →
- 02 How to Verify a Fix Actually Held Before and after windows done right, the confounders that fake a win, and when it's fair to call an improvement zero instead of stretching to find one. →
- 03 Minor Stops: The Losses Nobody Logs The two minute stop that never makes it onto anyone's radar, why a plant needs thresholds instead of a human judgment call, and how the short stops add up past the breakdowns. →
- 04 Planned vs Unplanned Downtime: The Line That Changes Every Number Where changeovers, PM windows, and breaks belong, and why moving that one line shifts your OEE, your Pareto, and your maintenance backlog all at once. →
- 05 Running a Kaizen Event Off Machine Data Instead of a Guess Pick the loss with a real dollar figure behind it, walk in with an evidence pack instead of a hunch, and measure the week after to know if it actually stuck. →
- 06 Shift Targets People Actually Believe How to set a real target from a routing instead of a guess, the mold time trap that wrecks a target without anyone noticing, and how to revise one without starting an argument. →
- 07 What a Golden Run Is, and Why It Beats a Nameplate Rate The best sustained stretch a machine has actually run, as the speed reference. Why it beats a spec sheet number, and how drift away from it shows up. →
- 08 Why Your Best Run Disappears Setpoint drift, operator overrides, and tooling wear all erode a machine's best pace the same slow way. How to actually see it happening in the cycle trace. →
- 09
6 min read
Is My OEE Good or Bad? What Other Shops Actually Run World-class OEE is 85 percent. Most plants run closer to 60 percent. See the real OEE benchmarks, why your number probably looks low, and what to aim for. → - 10
9 min read
Downtime Reason Codes Operators Will Actually Use Fewer codes beat more codes. What a usable downtime reason list looks like per vertical, a policy for stops too short to ask about, and coding at shift end. → - 11
8 min read
Your OEE Dropped Because You Started Measuring Everything Automated OEE almost always reads lower than the clipboard number it replaces. Why that's the number to trust, and what your first accurate month is actually for. → - 12
8 min read
Questions to Ask an OEE Vendor Before You Sign The measurement questions worth asking before a pilot: shift schedules, unmeasurable machines, read-only access, and what happens when the vendor is wrong. → - 13
9 min read
Part Counts From a PLC Counter Rollover, resets, and why a counter beats a derived cycle signal. What a counter tag's delta math protects against, and what to check on day one. → - 14
9 min read
What to Put on a Wallboard Operators Actually Look At Most shop-floor TVs get ignored within a week. What earns a second glance, what's decoration, and how to avoid a wall of red nobody trusts. → - 15
9 min read
What Each Machine Signal Means: Naming a Tag's Role A counter, a run state, an alarm, a setpoint, a process value. Why the role you assign a tag matters more than what you happened to name it. → - 16
8 min read
What Is OEE and How Do You Calculate It? The OEE formula explained plainly, with a worked example on one machine, the three factors that make it up, and why the textbook 85 percent target misleads more shops than it helps. → - 17
8 min read
TEEP vs OEE vs Utilization: Which Number Should You Use? OEE, TEEP, and utilization answer three different questions. What each one measures, a worked example on the same machine, and which one to actually report to which audience. → - 18
9 min read
The Six Big Losses, Mapped to What Modern Monitoring Actually Sees The classic TPM six big losses framework, checked against what a machine-connected system can actually detect automatically versus what still needs a human to say what happened. → - 19
8 min read
The Hidden Factory: The Capacity You Already Own The term for the output a plant could produce with equipment it already has, if the invisible losses were fixed. What makes up the hidden factory, and how to find it before spending on new capacity. → - 20
8 min read
The First Dollar Finding: What Week One Usually Turns Up What the first priced loss looks like once real data starts flowing, why it is usually a changeover or a minor stop instead of a big breakdown, and how to react to it. → - 21
8 min read
What to Show the Plant Manager in Week One The three screens worth putting in front of a plant manager after the first week of real data, the one number that matters most, and what to hold back until later. → - 22
8 min read
Why OEE Alone Does Not Change Behavior A percentage nobody owns versus a dollar figure someone does. Why OEE on its own rarely drives a fix, and what turns the same data into action. → - 23
8 min read
From Pilot to Plant: A Rollout Order That Holds Up The sequence that works after a pilot proves itself: rates before dashboards, who owns coding a stop, and when the second gateway actually earns its place. → - 24
8 min read
What Verified Savings Actually Means Before and after windows, attribution versus causation, and why a ledger that can show zero is worth more than one that can only show a win. → - 25
~8 min
What Spall's AI Learns From Your Machines, and What It Does With It A per-machine model forms automatically from telemetry, production, and downtime history already flowing in. What it learns, what it needs, and where it stays silent. → - 26
~7 min
How AutoML Turns Your Best Run Into a Live Reference The AI mines every completed cycle for the fastest sustained stretch a machine has run, then watches recent cycles against it continuously, with the chart and the dollar figure behind the finding. → - 27
~7 min
How to Read an Insight Card: Evidence, Confidence, and the Blank That Means Something Anatomy of an ML insight card: what the title claims, what the evidence backs it with, what the dollar figure means, and what a blank or a learning state is actually saying. → - 28
8 min read
Energy Cost per Part: Reading Power Draw Against Production How to turn a machine's metered kWh into a real dollar figure per part, why idle time skews the number, and what the Energy page prices today. → - 29
8 min read
Shift Attribution: Getting a Stop on the Right Shift How Spall decides which shift a stop or a part belongs to, why cross-midnight and rotating patterns trip it up, and what a wrong schedule does to every downstream number. →
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