Net OEE

73.72%
82.21%
86.57%
80.83%
Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.1646
Cost Weighted
OEE Factors

Availability
27.7%
29.7%
30.6%
87.98%
Actual Cost
$
1.9191
$
0.5754
$
0.2525
$
0.4175
$
3.1646

Date:
Weighted SHIFT OEE
Performance
Quality
28.2%
30.1%
31.5%
33.6%
33.1%
35.3%
92.80%
99.00%
Gain (Loss)
Weighted
$
(0.0191) 0.6004
$
(0.1103) 0.1470
$
(0.0025) 0.0790
$
(0.0800) 0.1066
$
(0.2120) 0.9330

Net OEE

Availability

Weighted Hourly OEE

Performance
Quality

Vergence Business Associates - Manufacturing Consultants - Shift Production Summary

Part Data
Rate
Per Hour
Per Minute
IDEAL Cycle Time (Seconds):
15
IDEAL
240
4.00
OEE - Current Index:
80.00%
PLAN (OEE)
192
3.20
Direct Labour Rate: $
25.00
Labour
$
111.63 $
1.86
Direct Labour (Count):
4
Burden (Indirect) $
81.00 $
1.35
Material Content (Per Part): $
1.90
Process Cost
$
192.63 $
3.21
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate.
Total Minutes / Shift (8 hours):
Prorated = Total / Net Available Minutes
480
2 Paid 10 Minute Breaks:
Prorated Rate Factor: 480 / 430 =
20
1.1163
1 Paid 20 Minute Meal Break:
20
Company / Plant Wide Meetings:
Prorated Labour Rate: $
0
27.91
5 Minute Shift Meeting:
Burden Costs
5
5 Minute Clean Up:
5
Direct (Parts)
Indirect
Total
Net Available Work Time:
430
$
0.25 $
81.00 $
81.25
Production Run Time
Start
Stop
11:00 PM
11:05 PM
11:05 PM
12:00 AM
12:00 AM
1:00 AM
1:00 AM
1:10 AM
1:10 AM
2:00 AM
2:00 AM
3:00 AM
3:00 AM
3:20 AM
3:20 AM
4:00 AM
4:00 AM
5:00 AM
5:00 AM
5:20 AM
5:20 AM
5:30 AM
5:30 AM
6:00 AM
6:00 AM
6:55 AM
6:55 AM
7:00 AM
TOTALS

Shift
Night
1
2
3
4
5
6
7

8
Night

Production Downtime Summary

Total Scheduled Time:
Planned Down Time:
Net Available Time:
Unplanned Down Time:
Actual Operating Time:

Labour
480.0
Prorated
50.0
Prorated
430.0 $
800.00
73.0 $
135.81
357.0 $
664.19

Cost Base
Material
Labour
Burden (Direct)
Burden (Indirect)
Total Part Cost
Total Costs
Material
Labour
Burden (Direct)
Burden (Indirect)
Total
X-Check
Actual Part Cost

Minutes

Schedule
IDEAL

Plan (OEE)

Total

5.0
55.0
60.0
10.0
50.0
60.0
20.0
40.0
60.0
20.0
10.0
30.0
55.0
5.0
480.0

20
220
240
40
200
240
80
160
240
80
40
120
220
20
1920

16
176
192
32
160
192
64
128
192
64
32
96
176
16
1536

0
145
172
0
120
210
0
151
202
42
0
45
193
0
1280

Burden (Indirect)
Prorated
Prorated
$
580.50
$
98.55
$
481.95

Operating Time Summary

IDEAL:
320.0
Quality Loss:
3.0
Net IDEAL:
317.0
Actual:
357.0
Performance Loss:
37.0

$
$
$
$
$

Labour
595.35
5.58
589.77
664.19
68.84

$
$
$
$
$
$
$
$
$
$
$
$
$

Standard Cost
%
1.9000
64.35%
Shift
0.4651
15.75%
Night
0.2500
8.47%
Day
0.3375
11.43%
Afternoon
2.9526
100.00%
Total
Standard
Actual
OEE Factor
7,924.90 $
8,004.70
99.00%
1,940.00 $
2,400.00
80.83%
1,042.75 $
1,053.25
99.00%
1,407.71 $
1,741.50
80.83%
12,315.36 $
13,199.45
93.30%
12,315.36 $
13,199.45 $
884.09
3.1646
93.30%
TEST Function
0.9623 $
0.9801 $
0.9906
Production
Scrap
Hold
Test
0
1
0
0
2
0
0
0
1
0
0
0
1
0
5

Burden (Indirect)
$
432.00
$
4.05
$
427.95
$
481.95
$
49.95

0
2

0
2

1
0

1
0

1
0

0
3

0
4

Production (Quantity) Summary

Total Produced:
1280
Quality LOSS:
12
Total Accepted:
1268
Total Standard Operating Cost:
Total Actual Operating Cost:

Overall Equipment Effectiveness and Cost Summary

Availability
Performance
Quality
OEE
Cost
83.02%
89.64%
99.06%
73.72%
$
388.58
89.07%
93.21%
99.02%
82.21%
$
275.70
91.86%
95.25%
98.94%
86.57%
$
219.80
87.98%
92.80%
99.00%
80.83%
$
884.09
Availability
Performance
Quality
Total
Variance OEE
$
$
$
79.80 $
79.80 $
79.80
$
288.37 $
152.09 $
19.53 $
460.00 $
460.00
$
$
$
10.50 $
10.50 $
10.50
$
209.25 $
110.36 $
14.18 $
333.79 $
333.79
$
497.62 $
262.46 $
124.01 $
884.09 $
884.09
Cost Weighted
96.23%
97.93%
99.00%
93.30%
OEE Factors
$
497.62 $
262.46 $
124.01 $
884.09
$ 12,701.83 $
12,439.37 $
12,315.36
Downtime
Comments
Time
Class
Type
5.0
16.0
8.0
10.0
12.0
5.0
20.0
2.0
5.0
5.0
10.0
15.0
5.0
5.0
123.0

$
$
$
$
$

Material
2,432.00
22.80
2,409.20
3,743.92
4,132.50

Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Burden (Direct)
$
320.00
$
3.00
$
317.00
Total Efficiency:
Total Losses:

Meeting

Available
430.00
430.00
430.00
1290.00
Production
Total
Scrap
Hold
Test
Accepted
% of Shift
% of Total

Available

Shift Meeting

5.00
55.00
60.00

Break
50.00
60.00
Break
40.00
60.00
20.00
Break
30.00
55.00
Shift Clean Up
73.0
Net Available Time
430.0
OEE Summary
Material
Availability
83.02%
$
Performance
89.64%
$
Quality
99.06%
$
22.80
OEE
73.72%
$
22.80
90.60%
Actual Cost / Part: $
1.9180
$
388.58
Actual Loss / Part: $
0.0180
Loss Cross Check:
99.06%

$
$
$
$
$
$

Labour
135.81
68.84
5.58
210.23
0.6309
0.1658
73.72%

Time Reconciliation
Lost
160.00
123.00
103.75
386.75
Afternoon
1505
9
3
4
1489
98.94%
35.34%

Operating
357.00
383.00
395.00
1135.00
Night
1280
5
3
4
1268
99.06%
30.10%

Earned
320.00
357.00
376.25
1053.25
Day
1428
5
4
5
1414
99.02%
33.56%

Operating

Time Reconciliation (Minutes)

Earned
Lost
Performance

0.00
39.00
52.00
0.00
38.00
55.00
0.00
38.00
55.00
15.00
0.00
15.00
50.00
0.00
357.00
Burden (Direct)
$
$
$
3.00
$
3.00
$
0.2524
$
0.0024
99.06%

0.00
36.25
43.00
0.00
30.00
52.50
37.75
50.50
10.50
11.25
48.25
0.00
320.00
Burden (Indirect)
$
98.55
$
49.95
$
4.05
$
152.55
$
0.4578
$
0.1203
73.72%

$
$
$
$
$
$

5.00
18.75
17.00
10.00
20.00
7.50
20.00
2.25
9.50
9.50
10.00
18.75
6.75
5.00
160.00
Total Loss
234.36
118.79
35.43
388.58
2.9526
3.2591

Performance
37.00
26.00
18.75
81.75
Totals
4213
19
10
13
4171
99.00%
99.00%

$
$
$
$
$

0.00
2.75
9.00
0.00
8.00
2.50
0.00
0.25
4.50
4.50
0.00
3.75
1.75
0.00
37.00
Loss / Part
0.1848
0.0937
0.0279
0.3065
0.3065

Quality
3.00
3.50
4.00
10.50
%
100.00%
0.45%
0.24%
0.31%
99.00%
<< Quality
<< Weighted

Quality
0.00
1.25
0.00
0.00
0.50
0.50
0.00
0.00
0.25
0.25
0.00
0.00
0.25
0.00
3.00
%
5.67%
2.87%
0.86%
9.40%
90.60%

Net Earned
317.00
353.50
372.25
1042.75
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function
Net Earned
0.00
35.00
43.00
0.00
29.50
52.00
0.00
37.75
50.25
10.25
0.00
11.25
48.00
0.00
317.00
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function

Availability
83.02%
89.07%
91.86%
87.98%
Availability
100.00%
87.98%
100.00%
87.98%
$
0.1193
96.23%
$
3.0453
$
0.1193
Availability

OEE Cross Check

Quality
OEE
99.06%
73.72%
99.02%
82.21%
98.94%
86.57%
99.00%
80.83%
Quality
OEE Rate
99.00%
99.00%
99.00%
80.83%
99.00%
99.00%
99.00%
80.83%
$ 0.0297 $ 0.2120
99.00%
93.30%
$ 2.9526 $
0.2120
$ 0.0297 $ 0.2120
Hourly OEE
Performance
Quality
OEE

Performance
89.64%
93.21%
95.25%
92.80%
Performance
100.00%
92.80%
100.00%
92.80%
$
0.0629
97.93%
$
2.9823
$
0.0629

0.0%
70.9%
86.7%
0.0%
76.0%
91.7%
0.0%
95.0%
91.7%
75.0%
0.0%
50.0%
90.9%
0.0%
83.02%

0.0%
92.9%
82.7%
0.0%
78.9%
95.5%
0.0%
99.3%
91.8%
70.0%
0.0%
75.0%
96.5%
0.0%
89.64%

0.0%
96.6%
100.0%
0.0%
98.3%
99.0%
0.0%
100.0%
99.5%
97.6%
0.0%
100.0%
99.5%
0.0%
99.1%

0.0%
63.6%
71.7%
0.0%
59.0%
86.7%
0.0%
94.4%
83.8%
51.3%
0.0%
37.5%
87.3%
0.0%
73.72%

0.0%
63.6%
71.7%
0.0%
59.0%
86.7%
0.0%
94.4%
83.8%
51.3%
0.0%
37.5%
87.3%
0.0%
73.72%

0.0%
9.1%
12.1%
0.0%
8.8%
12.8%
0.0%
8.8%
12.8%
3.5%
0.0%
3.5%
11.6%
0.0%
83.02%

Availability
100.00%
83.02%
100.00%
83.02%
$
0.1848
94.33%
$
3.0742
$
0.1848

Performance
100.00%
89.64%
100.00%
89.64%
$
0.0937
96.95%
$
2.9806
$
0.0937

Quality
99.06%
99.06%
99.06%
99.06%
$ 0.0279
99.06%
$ 2.9526
$ 0.0279

OEE Rate
99.06%
73.72%
99.06%
73.72%
$ 0.3065
90.60%
$
0.3065
$ 0.3065

Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.2591
Cost Weighted
OEE Factors

Actual Cost
$
1.9180
$
0.6309
$
0.2524
$
0.4578
$
3.2591

0.0%
10.2%
12.0%
0.0%
8.4%
14.7%
0.0%
10.6%
14.1%
2.9%
0.0%
3.2%
13.5%
0.0%
89.64%

$
$
$
$
$

0.0%
10.9%
13.4%
0.0%
9.2%
16.3%
0.0%
11.8%
15.7%
3.2%
0.0%
3.5%
15.0%
0.0%
99.06%

Gain (Loss)
Weighted
(0.0180) 0.5830
(0.1658) 0.1427
(0.0024) 0.0767
(0.1203) 0.1036
(0.3065) 0.9060

17-Jan-09
OEE
24.6%
27.4%
28.9%
80.83%
Multiplier
0.6500
0.1949
0.0855
0.1414
1.0718

OEE
0.0%
8.1%
10.0%
0.0%
6.9%
12.1%
0.0%
8.8%
11.7%
2.4%
0.0%
2.6%
11.2%
0.0%
73.72%
Multiplier
0.6496
0.2137
0.0855
0.1551
1.1038

Vergence Business Associates - Manufacturing Consultants

Printed: 12/10/2014 / 11:23 AM

Toronto, Ontario, Canada

Page 1 of 10

Net OEE
73.72%
82.21%
86.57%
80.83%
Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.1646
Cost Weighted
OEE Factors

Availability
27.7%
29.7%
30.6%
87.98%
Actual Cost
$
1.9191
$
0.5754
$
0.2525
$
0.4175
$
3.1646

Date:
Weighted SHIFT OEE
Performance
Quality
28.2%
30.1%
31.5%
33.6%
33.1%
35.3%
92.80%
99.00%
Gain (Loss)
Weighted
$
(0.0191) 0.6004
$
(0.1103) 0.1470
$
(0.0025) 0.0790
$
(0.0800) 0.1066
$
(0.2120) 0.9330

Net OEE

Availability

Weighted Hourly OEE

Performance
Quality

Vergence Business Associates - Manufacturing Consultants - Shift Production Summary

Part Data
Rate
Per Hour
Per Minute
IDEAL Cycle Time (Seconds):
15
IDEAL
240
4.00
OEE - Current Index:
80.00%
PLAN (OEE)
192
3.20
Direct Labour Rate: $
25.00
Labour
$
111.63 $
1.86
Direct Labour (Count):
4
Burden (Indirect) $
81.00 $
1.35
Material Content (Per Part): $
1.90
Process Cost
$
192.63 $
3.21
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate.
Total Minutes / Shift (8 hours):
Prorated = Total / Net Available Minutes
480
2 Paid 10 Minute Breaks:
Prorated Rate Factor: 480 / 430 =
20
1.1163
1 Paid 20 Minute Meal Break:
20
Company / Plant Wide Meetings:
Prorated Labour Rate: $
0
27.91
5 Minute Shift Meeting:
Burden Costs
5
5 Minute Clean Up:
5
Direct (Parts)
Indirect
Total
Net Available Work Time:
430
$
0.25 $
81.00 $
81.25
Production Run Time
Start
Stop
7:00 AM
7:05 AM
7:05 AM
8:00 AM
8:00 AM
9:00 AM
9:00 AM
9:10 AM
9:10 AM
10:00 AM
10:00 AM
11:00 AM
11:00 AM
11:20 AM
11:20 AM
12:00 PM
12:00 PM
1:00 PM
1:00 PM
1:20 PM
1:20 PM
1:30 PM
1:30 PM
2:00 PM
2:00 PM
2:55 PM
2:55 PM
3:00 PM
TOTALS

Shift
Day
1
2
3
4
5
6
7

8
Day

Production Downtime Summary

Total Scheduled Time:
Planned Down Time:
Net Available Time:
Unplanned Down Time:
Actual Operating Time:

Labour
480.0
Prorated
50.0
Prorated
430.0 $
800.00
47.0 $
87.44
383.0 $
712.56

$
$
$

Cost Base
Material
Labour
Burden (Direct)
Burden (Indirect)
Total Part Cost
Total Costs
Material
Labour
Burden (Direct)
Burden (Indirect)
Total
X-Check
Actual Part Cost

Minutes

Schedule
IDEAL

Plan (OEE)

Total

5.0
55.0
60.0
10.0
50.0
60.0
20.0
40.0
60.0
20.0
10.0
30.0
55.0
5.0
480.0

20
220
240
40
200
240
80
160
240
80
40
120
220
20
1920

16
176
192
32
160
192
64
128
192
64
32
96
176
16
1536

0
145
190
0
145
217
0
140
230
70
0
83
208
0
1428

Burden
Prorated
Prorated
580.50
63.45
517.05

Operating Time Summary

IDEAL:
Quality Loss:
Net IDEAL:
Actual:
Performance Loss:

357.0
3.5
353.5
383.0
26.0

$
$
$
$
$

Labour
664.19
6.51
657.67
712.56
48.37

$
$
$
$
$
$
$
$
$
$
$
$
$

Standard Cost
%
1.9000
64.35%
Shift
0.4651
15.75%
Night
0.2500
8.47%
Day
0.3375
11.43%
Afternoon
2.9526
100.00%
Total
Standard
Actual
OEE Factor
7,924.90 $
8,004.70
99.00%
1,940.00 $
2,400.00
80.83%
1,042.75 $
1,053.25
99.00%
1,407.71 $
1,741.50
80.83%
12,315.36 $
13,199.45
93.30%
12,315.36 $
13,199.45 $
884.09
3.1646
93.30%
TEST Function
0.9623 $
0.9801 $
0.9906
Production
Scrap
Hold
Test
0
1
0
0
2
0
0
0
1
0
0
0
1
0
5

$
$
$
$
$

Burden
481.95
4.73
477.23
517.05
35.10

0
2

0
2

1
0

1
0

Overall Equipment Effectiveness and Cost Summary

Availability
Performance
Quality
OEE
Cost
83.02%
89.64%
99.06%
73.72%
$
388.58
89.07%
93.21%
99.02%
82.21%
$
275.70
91.86%
95.25%
98.94%
86.57%
$
219.80
87.98%
92.80%
99.00%
80.83%
$
884.09
Availability
Performance
Quality
Total
Variance OEE
$
$
$
79.80 $
79.80 $
79.80
$
288.37 $
152.09 $
19.53 $
460.00 $
460.00
$
$
$
10.50 $
10.50 $
10.50
$
209.25 $
110.36 $
14.18 $
333.79 $
333.79
$
497.62 $
262.46 $
124.01 $
884.09 $
884.09
Cost Weighted
96.23%
97.93%
99.00%
93.30%
OEE Factors
$
497.62 $
262.46 $
124.01 $
884.09
$ 12,701.83 $
12,439.37 $
12,315.36
Downtime
Comments
Time
Class
Type
5.0
15.0
10.0
10.0
12.0
5.0
20.0
0.0
0.0
0.0
10.0
5.0
0.0
5.0
97.0

1
0

1
0

0
4

1
0
5

Production (Quantity) Summary

Total Produced:
1428
Quality LOSS:
14
Total Accepted:
1414
Total Standard Operating Cost:
Total Actual Operating Cost:

$
$
$
$
$

Material
2,713.20
26.60
2,686.60
4,175.00
4,450.70

Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Burden (Direct)
$
357.00
$
3.50
$
353.50
Total Efficiency:
Total Losses:

Meeting

Available
430.00
430.00
430.00
1290.00
Production
Total
Scrap
Hold
Test
Accepted
% of Shift
% of Total

Available

Shift Meeting
55.00
60.00
Break
50.00
60.00
Break
40.00
60.00
20.00
Break
30.00
55.00
Shift Clean Up

47.0
OEE Summary
Availability
89.07%
Performance
93.21%
Quality
99.02%
OEE
82.21%
93.81%
Standard Costs:
$
275.70
Actual Cost:
Loss Cross Check:

Material
$
$
$
$
$
$

26.60
26.60
1.9000
1.9188
99.02%

$
$
$
$
$
$

430.00
Labour
87.44
48.37
6.51
142.33
0.4651
0.5658
82.21%

Time Reconciliation
Lost
160.00
123.00
103.75
386.75
Afternoon
1505
9
3
4
1489
98.94%
35.34%

Operating
357.00
383.00
395.00
1135.00
Night
1280
5
3
4
1268
99.06%
30.10%

Earned
320.00
357.00
376.25
1053.25
Day
1428
5
4
5
1414
99.02%
33.56%

Operating

Time Reconciliation (Minutes)

Earned
Lost
Performance

0.00
40.00
50.00
0.00
38.00
55.00
0.00
40.00
60.00
20.00
0.00
25.00
55.00
0.00
383.00
Burden (Direct)
$
$
$
3.50
$
3.50
$
0.2500
$
0.2525
99.02%

0.00
36.25
47.50
0.00
36.25
54.25
35.00
57.50
17.50
20.75
52.00
0.00
357.00
Burden (Indirect)
$
63.45
$
35.10
$
4.73
$
103.28
$
0.3375
$
0.4105
82.21%

$
$
$
$
$
$

5.00
18.75
12.50
10.00
13.75
5.75
20.00
5.00
2.50
2.50
10.00
9.25
3.00
5.00
123.00
Total
150.89
83.47
41.34
275.70
2.9526
3.1476

Performance
37.00
26.00
18.75
81.75
Totals
4213
19
10
13
4171
99.00%
99.00%

Quality
3.00
3.50
4.00
10.50
%
100.00%
0.45%
0.24%
0.31%
99.00%
<< Quality
<< Weighted

Quality

0.00
3.75
2.50
0.00
1.75
0.75
0.00
5.00
2.50
2.50
0.00
4.25
3.00
0.00
26.00
Loss per Part
$
0.1067
$
0.0590
$
0.0292
$
0.1950

%
3.39%
1.88%
0.93%
6.19%

93.81%

0.1950

0.00
1.25
0.00
0.00
0.50
0.50
0.00
0.00
0.50
0.25
0.00
0.00
0.50
0.00
3.50

Net Earned
317.00
353.50
372.25
1042.75
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function
Net Earned
0.00
35.00
47.50
0.00
35.75
53.75
0.00
35.00
57.00
17.25
0.00
20.75
51.50
0.00
353.50
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function

Availability
83.02%
89.07%
91.86%
87.98%
Availability
100.00%
87.98%
100.00%
87.98%
$
0.1193
96.23%
$
3.0453
$
0.1193
Availability

OEE Cross Check

Quality
OEE
99.06%
73.72%
99.02%
82.21%
98.94%
86.57%
99.00%
80.83%
Quality
OEE Rate
99.00%
99.00%
99.00%
80.83%
99.00%
99.00%
99.00%
80.83%
$ 0.0297 $ 0.2120
99.00%
93.30%
$ 2.9526 $
0.2120
$ 0.0297 $ 0.2120
Hourly OEE
Performance
Quality
OEE

Performance
89.64%
93.21%
95.25%
92.80%
Performance
100.00%
92.80%
100.00%
92.80%
$
0.0629
97.93%
$
2.9823
$
0.0629

0.0%
72.7%
83.3%
0.0%
76.0%
91.7%
0.0%
100.0%
100.0%
100.0%
0.0%
83.3%
100.0%
0.0%
89.07%

0.0%
90.6%
95.0%
0.0%
95.4%
98.6%
0.0%
87.5%
95.8%
87.5%
0.0%
83.0%
94.5%
0.0%
93.21%

0.0%
96.6%
100.0%
0.0%
98.6%
99.1%
0.0%
100.0%
99.1%
98.6%
0.0%
100.0%
99.0%
0.0%
99.0%

0.0%
63.6%
79.2%
0.0%
71.5%
89.6%
0.0%
87.5%
95.0%
86.2%
0.0%
69.2%
93.6%
0.0%
82.21%

0.0%
63.6%
79.2%
0.0%
71.5%
89.6%
0.0%
87.5%
95.0%
86.2%
0.0%
69.2%
93.6%
0.0%
82.21%

0.0%
9.3%
11.6%
0.0%
8.8%
12.8%
0.0%
9.3%
14.0%
4.7%
0.0%
5.8%
12.8%
0.0%
89.07%

Availability
100.00%
89.07%
100.00%
89.07%
$
0.1067
96.61%
$
3.0409
$
0.1067

Performance
100.00%
93.21%
100.00%
93.21%
$
0.0590
98.06%
$
2.9819
$
0.0590

Quality
99.02%
99.02%
99.02%
99.02%
$ 0.0292
99.02%
$ 2.9526
$ 0.0292

OEE Rate
99.02%
82.21%
99.02%
82.21%
$ 0.1950
93.81%
$
0.1950
$ 0.1950

Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.1476
Cost Weighted
OEE Factors

Actual Cost
$
1.9188
$
0.5658
$
0.2525
$
0.4105
$
3.1476

0.0%
9.5%
12.4%
0.0%
9.5%
14.2%
0.0%
9.1%
15.0%
4.6%
0.0%
5.4%
13.6%
0.0%
93.21%

$
$
$
$
$

0.0%
9.8%
13.3%
0.0%
10.0%
15.1%
0.0%
9.8%
16.0%
4.8%
0.0%
5.8%
14.4%
0.0%
99.02%

Gain (Loss)
Weighted
(0.0188) 0.6036
(0.1007) 0.1478
(0.0025) 0.0794
(0.0730) 0.1072
(0.1950) 0.9381

17-Jan-09
OEE
24.6%
27.4%
28.9%
80.83%
Multiplier
0.6500
0.1949
0.0855
0.1414
1.0718

OEE
0.0%
8.1%
11.0%
0.0%
8.3%
12.5%
0.0%
8.1%
13.3%
4.0%
0.0%
4.8%
12.0%
0.0%
82.21%
Multiplier
0.6499
0.1916
0.0855
0.1390
1.0660

Vergence Business Associates - Manufacturing Consultants

Printed: 12/10/2014 / 11:23 AM

Toronto, Ontario, Canada

Page 2 of 10

Net OEE
73.72%
82.21%
86.57%
80.83%
Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.1646
Cost Weighted
OEE Factors

Availability
27.7%
29.7%
30.6%
87.98%
Actual Cost
$
1.9191
$
0.5754
$
0.2525
$
0.4175
$
3.1646

Date:
Weighted SHIFT OEE
Performance
Quality
28.2%
30.1%
31.5%
33.6%
33.1%
35.3%
92.80%
99.00%
Gain (Loss)
Weighted
$
(0.0191) 0.6004
$
(0.1103) 0.1470
$
(0.0025) 0.0790
$
(0.0800) 0.1066
$
(0.2120) 0.9330

Net OEE

Availability

Weighted Hourly OEE

Performance
Quality

Vergence Business Associates - Manufacturing Consultants - Shift Production Summary

Part Data
Rate
Per Hour
Per Minute
IDEAL Cycle Time (Seconds):
15
IDEAL
240
4.00
OEE - Current Index:
80.00%
PLAN (OEE)
192
3.20
Direct Labour Rate: $
25.00
Labour
$
111.63 $
1.86
Direct Labour (Count):
4
Burden (Indirect) $
81.00 $
1.35
Material Content (Per Part): $
1.90
Process Cost
$
192.63 $
3.21
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate.
Total Minutes / Shift (8 hours):
Prorated = Total / Net Available Minutes
480
2 Paid 10 Minute Breaks:
Prorated Rate Factor: 480 / 430 =
20
1.1163
1 Paid 20 Minute Meal Break:
20
Company / Plant Wide Meetings:
Prorated Labour Rate: $
0
27.91
5 Minute Shift Meeting:
Burden Costs
5
5 Minute Clean Up:
5
Direct (Parts)
Indirect
Total
Net Available Work Time:
430
$
0.25 $
81.00 $
81.25
Production Run Time
Start
Stop
3:00 PM
3:05 PM
3:05 PM
4:00 PM
4:00 PM
5:00 PM
5:00 PM
5:10 PM
5:10 PM
6:00 PM
6:00 PM
7:00 PM
7:00 PM
7:20 PM
7:20 PM
8:00 PM
8:00 PM
9:00 PM
9:00 PM
9:20 PM
9:20 PM
9:30 PM
9:30 PM
10:00 PM
10:00 PM
10:55 PM
10:55 PM
11:00 PM
TOTALS

Shift
Afternoon
1
2
3
4
5
6
7

8
Afternoon

Production Downtime Summary

Total Scheduled Time:
Planned Down Time:
Net Available Time:
Unplanned Down Time:
Actual Operating Time:

Labour
480.0
Prorated
50.0
Prorated
430.0 $
800.00
35.0 $
65.12
395.0 $
734.88

$
$
$

Cost Base
Material
Labour
Burden (Direct)
Burden (Indirect)
Total Part Cost
Total Costs
Material
Labour
Burden (Direct)
Burden (Indirect)
Total
X-Check
Actual Part Cost

Minutes

Schedule
IDEAL

Plan (OEE)

Total

5.0
55.0
60.0
10.0
50.0
60.0
20.0
40.0
60.0
20.0
10.0
30.0
55.0
5.0
480.0

20
220
240
40
200
240
80
160
240
80
40
120
220
20
1920

16
176
192
32
160
192
64
128
192
64
32
96
176
16
1536

0
198
224
0
138
227
0
148
232
38
0
107
193
0
1505

Burden
Prorated
Prorated
580.50
47.25
533.25

Operating Time Summary

IDEAL:
Quality Loss:
Net IDEAL:
Actual:
Performance Loss:

376.3
4.0
372.3
395.0
18.8

$
$
$
$
$

Labour
700.00
7.44
692.56
734.88
34.88

$
$
$
$
$
$
$
$
$
$
$
$
$

Standard Cost
%
1.9000
64.35%
Shift
0.4651
15.75%
Night
0.2500
8.47%
Day
0.3375
11.43%
Afternoon
2.9526
100.00%
Total
Standard
Actual
OEE Factor
7,924.90 $
8,004.70
99.00%
1,940.00 $
2,400.00
80.83%
1,042.75 $
1,053.25
99.00%
1,407.71 $
1,741.50
80.83%
12,315.36 $
13,199.45
93.30%
12,315.36 $
13,199.45 $
884.09
3.1646
93.30%
TEST Function
0.9623 $
0.9801 $
0.9906
Production
Scrap
Hold
Test
0
1
1
0
2
0
0
0
3
0
0
0
2
0
9

$
$
$
$
$

0
2

0
2

1
0

1
0

1
0

0
3

0
4

Burden
Production (Quantity) Summary
507.94 Total Produced:
1505
5.40
Quality LOSS:
16
502.54 Total Accepted:
1489
Total
Standard
Operating
Cost:
533.25
Total Actual Operating Cost:
25.31

Overall Equipment Effectiveness and Cost Summary

Availability
Performance
Quality
OEE
Cost
83.02%
89.64%
99.06%
73.72%
$
388.58
89.07%
93.21%
99.02%
82.21%
$
275.70
91.86%
95.25%
98.94%
86.57%
$
219.80
87.98%
92.80%
99.00%
80.83%
$
884.09
Availability
Performance
Quality
Total
Variance OEE
$
$
$
79.80 $
79.80 $
79.80
$
288.37 $
152.09 $
19.53 $
460.00 $
460.00
$
$
$
10.50 $
10.50 $
10.50
$
209.25 $
110.36 $
14.18 $
333.79 $
333.79
$
497.62 $
262.46 $
124.01 $
884.09 $
884.09
Cost Weighted
96.23%
97.93%
99.00%
93.30%
OEE Factors
$
497.62 $
262.46 $
124.01 $
884.09
$ 12,701.83 $
12,439.37 $
12,315.36
Downtime
Comments
Time
Class
Type
5.0
5.0
0.0
10.0
15.0
0.0
20.0
0.0
0.0
10.0
10.0
0.0
5.0
5.0
85.0

$
$
$
$
$

Material
2,859.50
30.40
2,829.10
4,396.45
4,616.25

Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Unplanned
Planned
Unplanned
Unplanned
Planned
Unplanned
Burden (Direct)
$
376.25
$
4.00
$
372.25
Total Efficiency:
Total Losses:

Meeting

Available
430.00
430.00
430.00
1290.00
Production
Total
Scrap
Hold
Test
Accepted
% of Shift
% of Total

Available

Shift Meeting
55.00
60.00
Break
50.00
60.00
Break
40.00
60.00
20.00
Break
30.00
55.00
Shift Clean Up

35.0
OEE Summary
Availability
91.86%
Performance
95.25%
Quality
98.94%
OEE
91.86%
95.24%
Standard Costs:
$
219.80
Actual Cost:
Loss Cross Check:

Material
$
$
$
$
$
$

30.40
30.40
1.9000
1.9204
98.94%

$
$
$
$
$
$

430.00
Labour
65.12
34.88
7.44
107.44
0.4651
0.5373
86.57%

Time Reconciliation
Lost
160.00
123.00
103.75
386.75
Afternoon
1505
9
3
4
1489
98.94%
35.34%

Operating
357.00
383.00
395.00
1135.00
Night
1280
5
3
4
1268
99.06%
30.10%

Earned
320.00
357.00
376.25
1053.25
Day
1428
5
4
5
1414
99.02%
33.56%

Operating

Time Reconciliation (Minutes)

Earned
Lost
Performance

0.00
50.00
60.00
0.00
35.00
60.00
0.00
40.00
60.00
10.00
0.00
30.00
50.00
0.00
395.00
Burden (Direct)
$
$
$
4.00
$
4.00
$
0.2500
$
0.2527
98.94%

0.00
49.50
56.00
0.00
34.50
56.75
37.00
58.00
9.50
26.75
48.25
0.00
376.25
Burden (Indirect)
$
47.25
$
25.31
$
5.40
$
77.96
$
0.3375
$
0.3899
86.57%

$
$
$
$
$
$

5.00
5.50
4.00
10.00
15.50
3.25
20.00
3.00
2.00
10.50
10.00
3.25
6.75
5.00
103.75
Total
112.37
60.20
47.24
219.80
2.9526
3.1002

Performance
37.00
26.00
18.75
81.75
Totals
4213
19
10
13
4171
99.00%
99.00%

Quality
3.00
3.50
4.00
10.50
%
100.00%
0.45%
0.24%
0.31%
99.00%
<< Quality
<< Weighted

Quality

0.00
0.50
4.00
0.00
0.50
3.25
0.00
3.00
2.00
0.50
0.00
3.25
1.75
0.00
18.75
Loss per Part
$
0.0755
$
0.0404
$
0.0317
$
0.1476

%
2.43%
1.30%
1.02%
4.76%

95.24%

0.1476

0.00
1.25
0.25
0.00
0.50
0.50
0.00
0.00
0.75
0.25
0.00
0.00
0.50
0.00
4.00

Net Earned
317.00
353.50
372.25
1042.75
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function
Net Earned
0.00
48.25
55.75
0.00
34.00
56.25
0.00
37.00
57.25
9.25
0.00
26.75
47.75
0.00
372.25
Cost Base
Material
Labour
Burden Direct
Burden Indirect
Total Cost
OEE (COST)
TEST Function

Availability
83.02%
89.07%
91.86%
87.98%
Availability
100.00%
87.98%
100.00%
87.98%
$
0.1193
96.23%
$
3.0453
$
0.1193
Availability

OEE Cross Check

Performance
Quality
OEE
89.64%
99.06%
73.72%
93.21%
99.02%
82.21%
95.25%
98.94%
86.57%
92.80%
99.00%
80.83%
Performance
Quality
OEE Rate
100.00%
99.00%
99.00%
92.80%
99.00%
80.83%
100.00%
99.00%
99.00%
92.80%
99.00%
80.83%
$
0.0629 $ 0.0297 $ 0.2120
97.93%
99.00%
93.30%
$
2.9823 $ 2.9526 $
0.2120
$
0.0629 $ 0.0297 $ 0.2120
Hourly OEE
Performance
Quality
OEE

0.0%
90.9%
100.0%
0.0%
70.0%
100.0%
0.0%
100.0%
100.0%
50.0%
0.0%
100.0%
90.9%
0.0%
91.86%

0.0%
99.0%
93.3%
0.0%
98.6%
94.6%
0.0%
92.5%
96.7%
95.0%
0.0%
89.2%
96.5%
0.0%
95.25%

0.0%
97.5%
99.6%
0.0%
98.6%
99.1%
0.0%
100.0%
98.7%
97.4%
0.0%
100.0%
99.0%
0.0%
98.9%

0.0%
87.7%
92.9%
0.0%
68.0%
93.8%
0.0%
92.5%
95.4%
46.3%
0.0%
89.2%
86.8%
0.0%
86.57%

0.0%
87.7%
92.9%
0.0%
68.0%
93.8%
0.0%
92.5%
95.4%
46.3%
0.0%
89.2%
86.8%
0.0%
86.57%

Availability
100.00%
91.86%
100.00%
91.86%
$
0.0755
97.57%
$
3.0248
$
0.0755

Performance
100.00%
95.25%
100.00%
95.25%
$
0.0404
98.66%
$
2.9843
$
0.0404

Quality
98.94%
98.94%
98.94%
98.94%
$ 0.0317
98.94%
$ 2.9526
$ 0.0317

OEE Rate
98.94%
86.57%
98.94%
86.57%
$ 0.1476
95.24%
$
0.1476
$ 0.1476

Standard Cost
$
1.9000
$
0.4651
$
0.2500
$
0.3375
$
2.9526
$
3.1002
Cost Weighted
OEE Factors

17-Jan-09
OEE
24.6%
27.4%
28.9%
80.83%
Multiplier
0.6500
0.1949
0.0855
0.1414
1.0718

OEE

11.6%
14.0%

12.5%
14.2%

12.8%
14.8%

11.2%
13.0%

8.1%
14.0%

8.7%
14.4%

9.0%
15.0%

7.9%
13.1%

9.3%
14.0%
2.3%

9.4%
14.7%
2.4%

9.8%
15.2%
2.5%

8.6%
13.3%
2.2%

7.0%
11.6%

6.8%
12.2%

7.1%
12.7%

6.2%
11.1%

95.25%

98.94%

91.86%
Actual Cost
$
1.9204
$
0.5373
$
0.2527
$
0.3899
$
3.1002

Gain (Loss)
Weighted
$
(0.0204) 0.6129
$
(0.0722) 0.1500
$
(0.0027) 0.0806
$
(0.0524) 0.1089
$
(0.1476) 0.9524

86.57%
Multiplier
0.6504
0.1820
0.0856
0.1320
1.0500

Vergence Business Associates - Manufacturing Consultants

Printed: 12/10/2014 / 11:23 AM

Toronto, Ontario, Canada

Page 3 of 10

Factor
Availability
Performance
Quality
World Class

World Class
90.0%
95.0%
99.5%
85.1%

CLASS
Planned
Unplanned
Other

Downtime
Planned
Meeting
Clean Up
Break
PM
Change Over
Setup
Other

wntime
Unplanned
Material
Labour
Quality
Stock Out
Change Over
Setup
Containers
Process
Equipment
Tooling
Maintenance
Utilities
Other

Vergence Business Associates - Manufacturing Consultants

Redge Semplonius - President & CEO
Toronto, Ontario, Canada
Lean Execution Advanced Strategy Team
Providing Solutions in Real Time for Real Results
Focus for Success
Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO900

- Manufacturing Consultants
- President & CEO
ario, Canada
nced Strategy Team
al Time for Real Results
Success
ality Systems (TS-16949, ISO9001)

Vergence Business Associates - Manufacturing Consultants

Redge Semplonius - President & CEO
Toronto, Ontario, Canada
Lean Execution Advanced Strategy Team
Providing Solutions in Real Time for Real Results
Focus For Success
Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO9001)
Instructions

The spreadsheet is not as complex as it may appear at first glance. The input portion is what we would consider typical of a n
calculations are all based on the concepts that we have introduced through our book and on line Blog (http://www.leanexecu
Data is entered into the "white" cells.

Burden Costs

Our spreadsheet provides for Direct and Indirect Burden costs. Identifying these costs requires careful consideration to costs
For the purposes of the model, we could create calculations to consider the direct burden allocation per part, however, we re

Excel Time Calculations

The difference between two TIMES or DATES is easily calculated by subtracting one from the other, however, Excel does not
The shift report is based on consecutive hours worked and considers the change date change at MIDNIGHT to be the start of
Daily Rates
Hours / Day
Minutes / Hour
Seconds / Minute

Hours
24
60
60

Per Day
24
1440
86400

We use this knowledge to calculate the difference between the start and stop times indicated on the shift report based on "c

All calculations on our spreadsheet are based minutes and seconds. A more refined resolution could be used if necessary, ho

Vergence Business Associates - Manufacturing Consultants

Redge Semplonius - President & CEO
Toronto, Ontario, Canada
Lean Execution Advanced Strategy Team
Providing Solutions in Real Time for Real Results
Focus For Success
Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO9001)

http://www.leanexecution.wordpress.com
http://www.leanexecution.tk

at we would consider typical of a normal production or manafucturing operation. The resulting

n line Blog (http://www.leanexecution.wordpress.com)

uires careful consideration to costs that are truly part related versus operational or facility oriented.
allocation per part, however, we recommend confirming your intentions with your Finance department.

e other, however, Excel does not allow "negative" values.

ge at MIDNIGHT to be the start of the next day.

ed on the shift report based on "consecutive" hours worked.

ion could be used if necessary, however, the time base chosen seems to fit most industry applications.

 Vergence Business Associates - Manufacturing Consultants

Toronto, Ontario, Canada - 14-Jun-09

Vergence Business Associates - Toronto, Ontario, Canada

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Advanced Lean Execution Team
Toronto, Ontario, Canada