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OEE measure

Overhaul OEE

July, 29 2022

Overhaul OEE

Why is OEE so abused in many of our operations where, despite expensive software ‘solutions’, we can find lots of data but very little useful information? It's time to overhaul OEE, well the use of it. not the actual calculation.

Why do so many managers ask for the ‘overall OEE’ for their whole operation - is that even a real question? In view of the above questions, I think that it’s about time the use of OEE is itself overhauled, if only to reset expectations for what is an extremely powerful improvement tool, if correctly applied.

Don't use OEE as a mallet

OEE is akin to a surgeon’s scalpel in that it is best used very precisely, with great care, in the right place. It is not a blunderbuss to be applied everywhere at the same time in order to collect huge amounts of useless data that will be wastefully analysed by a well-meaning central data ninja. All of this in the pursuit of some apparently important ‘Overall Equipment Effectiveness’ metric for the whole operation.

So, you may ask: how do we determine precisely the right place to apply OEE? That’s relatively easy. Just follow one of the 5 guiding principles of lean - Go Look See. When on  your visit to the production line, find your bottleneck. usually the one wit all the WIP building up in front of it.  This is the process on which to focus your initial  OEE investigation - even if it’s a purely manual operation, the tool still works.

Train the team how to capture the 6 big losses here and how to tackle them. Once the WIP in front of the operation has disappeared then, Go Look See where it has moved to and start again.

And when the data ninjas are screaming for their aggregated OEE data for the hungry gods in the corporate sky, ignore them as best as you can.  Save your teams the pain of pointless data gathering and focus on smashing bottlenecks in the value stream.  


6 big losses

The full suite of GENEO Software

GEN-OPS1 - SaaS platform for building and governing brilliant standards. Looking after the full cycle of a standard from cradle to grave and tracking competency.

TEMPO - optimising maintenance and long cycle work

my-CI - a mobile app for leaders to drive Continuous Improvement 

OEE is ready for an overhaul in the way we use it.
Reduce maintenance turnaround time by 50%!
  • TEMPO is a system that has been developed to radically reduce the time taken to perform complex maintenance activities on fixed assets or fleet. It is a simple yet intelligent way of organizing your maintenance activities to complete the maintenance turnaround in half the time.
  • By organizing work sequences for trades/technicians and building critical paths and dependencies, TEMPO quickly highlights lost time opportunities in the overall planned turnaround.
  • Applying standard work instructions with step-by-step guides for process confirmation, TEMPO visualizes real-time progress for short interval control, providing instant decision making to maintain compliance to plan.
  • By using TEMPO to plan and execute complex maintenance turnarounds our clients have achieved 50%+ reduction in downtime, giving a 10%+ improvement in fleet availability.
Reduce maintenance backlog by 60%!
  • Unlock valuable maintenance time and use it to reduce chronic backlogs or stubborn deferred defects.
  • Give technicians more time for proactive interventions.
Improve asset reliability by 18%!
  • Enjoy the knock-on benefit of backlog clearance and proactive activities, improving the reliability of your assets.
Increase continuous improvement engagement by 180%!
  • TEMPO’s easy-to-use Concerns and Ideas capture feature engages technicians in driving improvements that help improve turnarounds, reliability, and availability
  • Identify the classic wastes (transport, inventory, motion, waiting, over processing, over production, defect) in relation to your maintenance activities.
  • Expose supply chain, kitting, resourcing, workplace organization, sequencing, tooling, and planning opportunities for review through TEMPO’s powerful reporting feature.
  • Analyze the hour-by-hour compliance to plan with the associated losses incurred throughout the turnaround event.
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