# Required OEE for OEM Volume Calculator

> Source: https://netray.co/tools/required-oee-for-oem-volume-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Back solve the OEE a cell needs to deliver a customer volume plus flex, and see the headroom or shortfall at your current OEE.

## Category

mes-shop-floor

## Industry

Automotive

## Audience

- Industrial engineer
- Plant manager
- Quoting engineer

## Tool

**Kind:** calculator

**Inputs:**

#### Annual customer volume

**Key:** demand

**Type:** number

**Default:** 480000

**Min:** 0

**Step:** 5000

**Unit:** pcs/yr

#### Peak flex requested by customer

**Key:** flex

**Type:** slider

**Default:** 15

**Min:** 0

**Max:** 40

**Step:** 1

**Unit:** %

**Help:** Capacity above nominal that the customer asks you to support.

#### Working days per year

**Key:** days

**Type:** number

**Default:** 240

**Min:** 1

**Max:** 365

**Step:** 1

**Unit:** days

#### Shifts per day

**Key:** shifts

**Type:** select

**Default:** 2

**Options:**

##### 1 shift

**Value:** 1

##### 2 shifts

**Value:** 2

##### 3 shifts

**Value:** 3

#### Hours per shift

**Key:** hours

**Type:** number

**Default:** 8

**Min:** 1

**Max:** 12

**Step:** 0.5

**Unit:** h

#### Paid breaks per shift

**Key:** breaks

**Type:** number

**Default:** 40

**Min:** 0

**Step:** 5

**Unit:** min

#### Planned downtime

**Key:** pd

**Type:** slider

**Default:** 6

**Min:** 0

**Max:** 30

**Step:** 1

**Unit:** %

**Help:** Preventive maintenance, changeover, trials.

#### Ideal cycle time

**Key:** ct

**Type:** number

**Default:** 22

**Min:** 0.1

**Step:** 0.5

**Unit:** sec

**Help:** Design cycle time per cycle at full speed.

#### Parts per cycle

**Key:** ppc

**Type:** number

**Default:** 2

**Min:** 1

**Step:** 1

**Unit:** pcs

#### Current OEE

**Key:** cur

**Type:** slider

**Default:** 72

**Min:** 30

**Max:** 95

**Step:** 1

**Unit:** %

**Outputs:**

#### Peak annual demand

**Key:** peak

**Expr:** demand * (1 + flex / 100)

**Format:** integer

#### Available seconds per day

**Key:** sec_day

**Expr:** shifts * (hours * 3600 - breaks * 60)

**Format:** integer

#### Planned production time per year

**Key:** planned

**Expr:** days * sec_day * (1 - pd / 100)

**Format:** integer

**Description:** Seconds.

#### Ideal capacity at 100 percent OEE

**Key:** ideal

**Expr:** planned / ct * ppc

**Format:** integer

**Description:** Parts per year if nothing ever went wrong.

#### Required OEE

**Key:** req

**Expr:** if(gt(ideal, 0), peak / ideal * 100, 0)

**Format:** percent

**Primary:** true

**Description:** Above 100 percent means the line cannot meet the demand as configured.

#### Capacity headroom at current OEE

**Key:** gap

**Expr:** ideal * cur / 100 - peak

**Format:** integer

**Primary:** true

**Description:** Negative means a shortfall in parts per year.

**Chart:**

#### Required OEE percent vs customer flex

**Type:** line

**X:** flex

**From:** 0

**To:** 40

**Steps:** 21

**Series:**

- req

**Disclaimer:** Planning estimate. It treats OEE as one blended factor and ignores seasonality, launch ramp and shared equipment.

## Content

**Intro:** When a customer asks for a volume with flex, the quoting question is simple: what OEE must this line run at to deliver it? This calculator turns shifts, breaks, planned downtime and ideal cycle time into a required OEE and shows how much headroom your current performance leaves.

**Sections:**

#### How to use it

**Body:** Enter annual volume and the peak flex the customer wants you to cover, usually stated as a percentage above nominal in the quotation package. Add calendar and shift data, then the ideal cycle time and parts per cycle from the process design. Finally enter your current OEE from the line or a similar one so the headroom result is meaningful.

**Bullets:**

- Use design cycle time, not observed average
- Subtract paid breaks only if the line stops for them
- Test several flex levels using the chart

#### The method

**Body:** Ideal capacity equals planned production time divided by ideal cycle time, times parts per cycle. Required OEE equals peak demand divided by that ideal capacity. OEE is availability times performance times quality, so a required figure of 85 percent needs a plan for each factor, not just a general target. Plants rarely sustain world class OEE across a full launch ramp.

#### Reading the result

**Body:** If required OEE is near or above what the line demonstrates today, the quote carries risk and you should add a second line, shift, or cycle time reduction. Many quoting teams keep a ceiling, such as 80 to 85 percent, to avoid committing to heroic performance. A negative headroom number shows the annual shortfall in parts.

#### Common mistakes

**Body:** Do not use nameplate speed as ideal cycle time when the process cannot run there. Do not forget that quality loss counts in OEE, so scrap increases required starts. Do not apply the calculation to a shared resource like a paint line without allocating its capacity among programs first.

**Cta:** Netray can help pull actual availability, performance and quality by work center from your ERP or MES so the current OEE input is measured rather than assumed.

**Faq:**

#### What OEE is realistic for automotive lines?

**Answer:** It varies widely by process and maturity. Many plants cite 65 to 85 percent as typical. Use your own demonstrated data per work center instead of an external benchmark when quoting.

#### Why include flex?

**Answer:** OEM release schedules often swing above the nominal volume in the nomination letter. Quoting only to nominal leaves no capacity for peak weeks, so suppliers commonly plan for a stated flex percentage.

#### Does it handle scrap?

**Answer:** Scrap is already inside OEE as quality loss. A lower first pass yield means the required OEE is harder to reach for the same good part demand.

#### Can I use it for a cell with several products?

**Answer:** Only if you allocate time to each product. Run the calculation per product with its share of planned time, then ensure the shares sum to one.

## Search terms

required OEE calculator, OEE needed to meet demand, automotive line capacity oee, oem volume flex capacity, quote capacity assumption oee, capacity planning ideal cycle time, how much oee do i need

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