OEE management audit: There is a perfect improvement process

For manufacturing companies that focus their value creation through plants, the analysis and targeted improvement of Overall Equipment Effectiveness (OEE) is a must. In companies, from “non-existent” to “fully automated and digitized”, you can find every expansion stage of OEE management. This audit list was developed to determine your own level of maturity.

If you want to determine the level of maturity of your own organization in OEE management, you can focus on the following audit questions. The audit sheet groups 13 requirements for a professional OEE management process into 3 categories. The more questions that can be answered with “yes” without reservation, the more sophisticated OEE management in one's own organization is. Every “no” is a field of action.

Criteria that a data collection must comply with:

1. There is a described OEE standard: Standards for OEE calculations are documented and are used to ensure consistency. For example, there is a standard for whether conversions, planned maintenance and/or breaks are included in the planned production time.
2. Basic information is correct: Information on production times and the loss base catalog is regularly reviewed to ensure accuracy and relevance.
3. OEE Standard covers all loss categories: Losses are separated into availability losses, performance losses and quality losses. These are calculated separately from each other and can therefore be analysed.
4. Ideal cycle times are precise: Accurate (verified) ideal cycle times are available for all products, which represent the maximum theoretical speed of the process (NOT “standard” speeds or “nameplate capacities” that are slower than the maximum).
5. Failure reasons and times are recorded: The reasons for all losses are recorded with a structured catalog. The criteria of simplicity (up to 10 reasons per level) and accuracy (automated recording of duration) are met.
6. Bottleneck is monitored: Information about the bottleneck in the process is recorded. Focusing improvement efforts on the bottleneck ensures optimal use of resources and is the fastest route to improved productivity.

Criteria that the Data presentation and analysis must comply with:

7. Information availability in real time: Real-time information enables employees to react proactively and ensures that they have easy access (e.g. via an Andon board) to the necessary information to achieve their shift goals.
8. Six major losses are tracked: The six major losses (armaments, failures, slow cycles, small stops, start-up losses, and production losses) are all traced to get a comprehensive understanding of lost productivity.
9. Largest losses are reported: For common periods of time, such as shifts and days, detailed reports on the most significant losses are available. These reports identify the most impactful areas of improvement and require the fewest measures to achieve substantial results.
10. Automated analysis: Algorithms analyze the data in real time and promptly identify anomalies such as clusters or trends.

Criteria set by management process must comply with:

11. Brief cycle discussion: As part of shop floor management, the figures, losses and reasons for loss are discussed daily between plant operators, supervisors and the improvement organization. Improvement activities are derived and followed up during implementation.
12. SMART goals are communicated: SMART goals (specific, measurable, attractive, realistic and time-specific) are effectively communicated to production employees and include goals for OEE, downtime, changeover time and/or good parts. Subsequent achievement of goals is publicly appreciated.
13. Training is formalized: There is a formal training program to provide all employees with a comprehensive understanding of OEE and associated losses. Employees can calculate and explain the OEE calculation themselves. Operators and supervisors can articulate their influence and strategies to improve metrics in their respective areas.

For easier use in day-to-day business, the audit catalog has been summarized on a PDF page and is available for free download:

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