OEE software
OEE calculation from the breakdowns you already log.
MaintenanceIQ handles the OEE calculation for each machine by deriving Availability from the breakdowns your team logs and taking Performance and Quality from shift logs picked up from your machine sensors, or entered by the supervisor where a machine has no sensor. It helps your plant head see overall equipment effectiveness per asset and across the plant, and helps your maintenance manager see how much of the loss is theirs to fix.
The problem
The OEE number on the whiteboard nobody can explain
Your plant head wants one number per line at the end of the day. Production writes output on a whiteboard, maintenance keeps downtime in its own sheet, and quality counts rejects somewhere else. By the time someone multiplies the three together, the figure is a week old and nobody can say why it moved.
The usual fix is an MES project: line counters, integration work and a long rollout before anyone sees a result. Many plants never get there, so OEE stays a monthly spreadsheet exercise.
There is a shorter path. Your maintenance team already logs breakdowns. If that record also supplies Availability, all that is left is the shift log, which your machine sensors can send through the same ingest your condition readings use. That is the approach MaintenanceIQ takes.
The formula
The OEE formula, term by term
Overall equipment effectiveness multiplies three factors. Each one is a share between 0 and 100 percent, so a weak factor pulls the whole score down.
OEE = Availability x Performance x Quality- Availability
- Run time ÷ Planned production time. Run time is planned time minus downtime. In MaintenanceIQ the downtime comes from the breakdowns logged against the machine.
- Performance
- Total count ÷ (Ideal rate x Run time). How close the machine ran to its ideal rate while it was running. The ideal rate is set once per asset.
- Quality
- Good count ÷ Total count. The share of output that was good the first time.
- Planned production time
- The time the machine was scheduled to run in the shift, before any stoppages.
Want to try the numbers first? Use the free OEE calculator.
How it works
How the OEE calculation works in MaintenanceIQ
Three inputs, two of which your team already produces.
- 01
Set the ideal rate
Your maintenance manager or process engineer sets the ideal rate for each asset once. It is the yardstick for Performance.
- 02
Log breakdowns as usual
Every stoppage your team records against the machine becomes downtime for Availability. Nobody enters downtime twice.
- 03
Pick up the shift log
Each shift's log, with the planned time, the total count and the good count, is picked up from the machine's sensors through the token-secured ingest. Where a machine has no sensor, the supervisor enters it in a minute.
- 04
Read the result
OEE and its three factors appear on the asset's Production tab. The Reliability page shows OEE across the plant with a worst-asset ranking.
Plant view
See where the losses sit, not just the score
A single OEE figure tells your plant head that something is wrong. The breakdown into Availability, Performance and Quality tells them who should act. Low Availability points at breakdowns and slow repairs, which maintenance owns. Low Performance points at speed loss and minor stops. Low Quality points at scrap and rework.
The worst-asset ranking on the Reliability page puts the machines dragging the plant down at the top, so the evening review starts with the right machine instead of the loudest complaint.
- OEE and its three factors per asset, on the Production tab
- Plant-wide OEE with a worst-asset ranking on the Reliability page
- Availability built from the breakdowns on each asset's record
- Plain arithmetic you can check by hand, no black box
Worked example
One shift on one press
Worked example (illustrative)
The HP-11 press (an illustrative machine) is planned to run an 8-hour shift, which is 480 minutes. Its ideal rate is set at 2 parts per minute. During the shift your team logs one breakdown of 45 minutes. At the end of the shift the log records a total count of 800 parts, of which 776 were good.
| Factor | Calculation | Result |
|---|---|---|
| Run time | 480 minus 45 minutes | 435 minutes |
| Availability | 435 ÷ 480 | 90.6% |
| Performance | 800 ÷ (2 x 435) | 92.0% |
| Quality | 776 ÷ 800 | 97.0% |
| OEE | 0.906 x 0.920 x 0.970 | 80.8% |
OEE for the shift is about 80.8%. The largest single loss is Availability, and it traces back to one logged breakdown, which gives your maintenance manager a specific job to look at.
More than a score
OEE that works with the rest of your maintenance
Because OEE lives on the same record as your work orders and preventive maintenance, it does more than report. The run-hours from the shift logs can feed a usage-based preventive maintenance meter, so a PM set for every 500 operating hours advances on its own. OEE quality is also one of the signals in each asset's Asset Risk (Beta) score.
The weekly reliability report that reaches admins and managers each Monday keeps the trend in front of the people who can act on it.
Frequently asked questions
Do I need an MES to track OEE?
No. Availability comes from the breakdowns your team already logs, and shift logs from your machine sensors, or entered by the supervisor where a machine has no sensor, supply Performance and Quality. There is no separate data-collection layer to stand up.
Is OEE calculated in real time?
Availability updates as breakdowns are logged. Performance and Quality update when each shift log arrives, so the figure is current shift by shift rather than minute by minute.
How does maintenance affect overall equipment effectiveness?
Maintenance most directly drives Availability, by reducing breakdowns and shortening repairs. Machine condition can also affect speed and defects, which show up in Performance and Quality.
Should I compare OEE between different machines?
With care. Machines with different processes and ideal rates are not directly comparable. OEE is most useful as a trend on one machine or line, and the worst-asset ranking shows where losses are largest.
Can I try the calculation without an account?
Yes. The free OEE calculator works out Availability, Performance, Quality and OEE from your own numbers.
Keep reading
Breakdown and downtime tracking
The breakdowns that supply OEE Availability.
ReadMTBF and MTTR analytics
How often machines fail and how long repairs take.
ReadOEE calculator
The formula, a worked example, and a free calculator.
ReadOEE for maintenance leaders
Use the losses, not the score, to choose the next job.
ReadMES vs CMMS
Which problem your plant is solving, and which to do first.
Read