Machine Efficiency Calculator

OEE = Availability × Performance × Quality. World-class OEE is 85%+ (87% for discrete manufacturing, 90% for process industry). Most Indian SMBs operate at 40–60% OEE — a significant gap representing untapped capacity. Improving from 50% to 70% OEE is equivalent to adding 40% capacity without any capital expenditure.

Equipment failure (unplanned downtime), setup and adjustment (changeover time), idling and minor stops (short stoppages under 5 minutes), reduced speed (below ideal cycle rate), process defects (rework and scrap), and reduced yield (startup losses until stable production). Tracking these six losses is the foundation of OEE improvement.

Implement Total Productive Maintenance (TPM): daily operator cleaning and inspection, weekly lubrication and adjustment, monthly major inspection, and proactive spare parts stocking for critical components. MTTR (Mean Time to Repair) can typically be reduced 50% in the first year of systematic TPM implementation.

SMED (Single Minute Exchange of Die) is a methodology to reduce changeover/setup time below 10 minutes. Steps: identify and separate internal (machine stopped) from external (done while running) setup activities, convert internal to external wherever possible, and streamline remaining internal steps. Typically reduces setup time 50–75%.

Every 1% improvement in OEE on a machine running 2 shifts (16 hours/day) adds 0.16 hours of productive time daily. On a machine producing ₹5,000 of output per hour, this adds ₹800 per day = ₹24,000 per month in capacity without additional cost. Multiple machines and higher OEE improvement multiply this dramatically.