1. Overall Equipment Effectiveness (OEE)
OEE = Availability × Performance × Quality
- Availability (%) = (Operating Time ÷ Planned Production Time) × 100
- Performance (%) = (Ideal Cycle Time × Total Count ÷ Operating Time) × 100
- Quality (%) = (Good Parts ÷ Total Parts Produced) × 100
2. Productivity
- Productivity = Output ÷ Input
- Labor Productivity = Total Output ÷ Total Labor Hours
- Machine Productivity = Output ÷ Machine Hours
3. Capacity Calculation
- Machine Capacity = Available Production Time ÷ Cycle Time
- Daily Capacity = (Production Hours × 60) ÷ Cycle Time
- Monthly Capacity = Daily Capacity × Working Days
4. Capacity Utilization
Capacity Utilization (%) =
(Actual Output ÷ Maximum Capacity) × 100
5. Takt Time
Takt Time =
Available Production Time ÷ Customer Demand
6. Cycle Time
Cycle Time =
Total Production Time ÷ Number of Units Produced
7. Throughput
Throughput =
Total Units Produced ÷ Time
8. Line Efficiency
Line Efficiency (%) =
(Total Work Content ÷ (Number of Stations × Cycle Time)) × 100
9. Balance Delay
Balance Delay (%) =
100 − Line Efficiency
10. Standard Time
- Standard Time = Normal Time + Allowances
OR
- Standard Time = Observed Time × Rating Factor × (1 + Allowance)
11. Normal Time
Normal Time =
Observed Time × Performance Rating
12. Manpower Requirement
- Manpower Required = Total Work Content ÷ Available Time per Operator
OR
- Manpower Required = Total Standard Hours ÷ Available Labor Hours
13. Overall Labor Efficiency
Labor Efficiency (%) =
(Standard Hours Produced ÷ Actual Hours Worked) × 100
14. Setup Reduction Improvement
Improvement (%) =
((Old Setup Time − New Setup Time) ÷ Old Setup Time) × 100
15. Rejection Rate
Rejection Rate (%) =
(Rejected Quantity ÷ Total Production) × 100
16. Rework Rate
Rework Rate (%) =
(Reworked Quantity ÷ Total Production) × 100
17. First Pass Yield (FPY)
FPY (%) =
(Good Units Produced First Time ÷ Total Units Produced) × 100
18. Scrap Rate
Scrap Rate (%) =
(Scrap Quantity ÷ Total Production) × 100
19. DPMO (Defects Per Million Opportunities)
DPMO =
(Total Defects ÷ (Total Units × Opportunities)) × 1,000,000
20. Process Capability (Cp)
Cp =
(USL − LSL) ÷ 6σ
21. Process Capability Index (Cpk)
Cpk =
Minimum of:
- (USL − Mean) ÷ 3σ
- (Mean − LSL) ÷ 3σ
22. Machine Utilization
Machine Utilization (%) =
(Machine Running Time ÷ Available Time) × 100
23. Downtime
Downtime (%) =
(Downtime ÷ Planned Production Time) × 100
24. MTBF (Mean Time Between Failures)
MTBF =
Total Operating Time ÷ Number of Failures
25. MTTR (Mean Time to Repair)
MTTR =
Total Repair Time ÷ Number of Repairs
26. Inventory Turnover
Inventory Turnover =
Annual Consumption ÷ Average Inventory
27. Lead Time
Lead Time =
Order Release Date − Order Receipt Date
28. Return on Investment (ROI)
ROI (%) =
(Net Annual Benefit ÷ Investment Cost) × 100