Production Baseline
Six Big Losses (minutes per day)
Availability Losses
Performance Losses
Quality Losses
TPM Loss Analysis
Enter production data and losses to analyze.
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What This Calculator Does
This Total Productive Maintenance loss analysis calculator categorizes production losses into the six big losses framework and calculates Overall Equipment Effectiveness (OEE) from availability, performance, and quality rates. The six big losses are: equipment breakdowns, setup and adjustments, minor stoppages and idling, reduced speed, process defects, and startup/yield losses. In 2026, OEE remains the gold standard for measuring manufacturing equipment productivity, with world-class OEE at 85% and the average discrete manufacturing plant achieving 60% to 67%.
The Formula
OEE multiplies three independent rates. Availability measures the percentage of planned production time the equipment is actually running (losses: breakdowns, setup/adjustment). Performance measures whether the equipment runs at its designed speed (losses: minor stoppages, reduced speed). Quality measures the percentage of output that meets specifications on the first pass (losses: process defects, startup rejects). Each rate is 0% to 100%, so OEE is always less than or equal to the lowest individual rate.
Step-by-Step Example
Enter production baseline
Planned production: 16 hours/day. Ideal cycle time: 30 seconds. Working days: 22/month.
Enter the six big losses
Breakdowns: 25 min/day. Setup: 35 min. Minor stoppages: 20 min. Speed loss: 30 min. Defects: 15 min. Startup: 10 min. Total: 135 min/day.
Enter financial data
Unit revenue: $15. Used to calculate the monthly revenue impact of losses.
Review OEE breakdown
Availability: 93.8%. Performance: 93.0%. Quality: 96.7%. OEE: 84.3%. Top loss: setup at 35 min/day. Monthly lost production: 5,940 units. Monthly lost revenue: $89,100.
Real-World Use Cases
Maintenance Manager Prioritizing Improvement Projects
Identify which of the six big losses contributes most to OEE loss and focus TPM pillar activities (autonomous maintenance, planned maintenance, focused improvement) on the highest-impact category.
Plant Manager Reporting Equipment Performance
Track OEE trends by machine, line, and plant to identify degradation, validate improvement projects, and benchmark against industry standards.
Continuous Improvement Team Running a Focused Improvement Kaizen
Use the loss breakdown to select the specific loss category for a kaizen event, set a measurable reduction target, and calculate the expected capacity and revenue recovery.
Common Mistakes to Avoid
Only tracking breakdowns and ignoring the other five losses. Breakdowns are the most visible loss but often account for less than 30% of total OEE loss. Minor stoppages and speed losses (the "hidden factory") are frequently larger.
Measuring OEE but not acting on the data. OEE is a diagnostic tool, not a goal in itself. Without structured problem-solving (5 Why, fishbone, PDCA) applied to the top losses, measuring OEE is just overhead.
Comparing OEE across different equipment types. An 85% OEE on a CNC machine and 85% on a packaging line mean very different things. Compare OEE for similar equipment and track improvement trends rather than absolute values.
Not distinguishing between planned and unplanned downtime. Planned maintenance and scheduled breaks should be excluded from available time (they reduce planned time, not availability). Only unplanned stops reduce the availability rate.
Frequently Asked Questions
Accuracy and Disclaimer
This calculator provides OEE and loss estimates based on your input data. Actual OEE measurement requires accurate recording of downtime events, speed losses, and quality data over time. Use this calculator for initial assessment and target setting. Implement automated data collection for ongoing OEE monitoring.
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