How to interpret and improve an OEE over 100

Overall Equipment Efficiency (OEE) is a key indicator for measuring production line performance. However, some plants have OEE values in excess of 100%, which may seem paradoxical. Understanding why this happens is crucial to effective corrective action. Such high OEE often reflects calculation errors or anomalies in production data. For optimized production, it is imperative to clarify these inconsistencies.

There are several possible reasons for an OEE higher than 100%. Firstly, it may result from an error in data collection or interpretation. Incorrect data, such as incorrectly recorded production times, lead to so-called ‘overruns’. This leads managers to make misguided decisions, affecting aspects such as financial losses, inefficient equipment management and erroneous estimates of overall plant performance.

To correct an abnormally high OEE, it is essential to review the entire process of calculating and analyzing production data. The use of digital tools such as TeepTrak for real-time performance monitoring can be a crucial lever. Particular attention needs to be paid to training in data collection, the use of correct KPIs and rigorous equipment management. This includes regular checking of machines to ensure that they are operating at their optimum power without recording errors.

Let’s consider the example of a manufacturing plant that observed OEEs in excess of 100% over several months. An in-depth analysis, coupled with the implementation of an OEE project with TeepTrak, revealed discrepancies in performance reports. By accurately calibrating tracking sensors and adjusting work schedules according to real needs, the company was able to bring its OEE down to a precise level, enabling consistent optimization without overestimating capacity.

For manufacturers, it’s imperative to structure a well-framed and documented OEE project. A rigorous approach includes conducting a data audit, training staff on best practices in performance verification and, if necessary, collaborating with solutions such as TeepTrak to benefit from complete visibility and in-depth analysis. In conclusion, avoiding the missteps associated with excessive OEE is a step towards improved long-term performance.

FAQ

Question 1: What does an OEE greater than 100% mean?

An OEE higher than 100% often indicates a data error or a misunderstanding in the calculation, as theoretically, the maximum OEE is 100%.

Question 2: How do I correct an incorrect OEE?

To rectify an erroneous OEE, it’s important to check the data used, recalibrate the machines and use analysis tools like TeepTrak for accurate tracking.

Question 3: What are the implications of an incorrect OEE?

Incorrect OEE can lead to uninformed decisions, increasing costs and reducing operational efficiency. Correcting these errors is vital to optimizing performance.