# Six Big Losses OEE Worksheet

> Source: https://netray.co/tools/six-big-losses-oee-worksheet
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

An editable worksheet that records the six big losses per line and shift in minutes, computes OEE per row and totals each loss as a share of planned time.

## Category

mes-shop-floor

## Audience

- Continuous improvement manager
- Production supervisor
- Plant manager

## Tool

**Kind:** worksheet

**Mode:** editable

**Columns:**

#### Line or machine

**Key:** line

**Type:** text

#### Shift

**Key:** shift

**Type:** select

**Options:**

- Day
- Evening
- Night

#### Planned production time (min)

**Key:** planned

**Type:** number

**Help:** Shift minutes less planned breaks and planned maintenance.

#### Equipment failure (min)

**Key:** breakdown

**Type:** number

**Help:** Availability loss. Stops from breakdowns.

#### Setup and adjustment (min)

**Key:** setup

**Type:** number

**Help:** Availability loss. Changeovers and adjustments.

#### Idling and minor stops (min)

**Key:** minor

**Type:** number

**Help:** Performance loss. Short stops, jams, blocked and starved.

#### Reduced speed (min)

**Key:** slow

**Type:** number

**Help:** Performance loss. Time lost running below ideal cycle time.

#### Process defects (min)

**Key:** defects

**Type:** number

**Help:** Quality loss. Scrap and rework units times ideal cycle time.

#### Startup rejects (min)

**Key:** startup

**Type:** number

**Help:** Quality loss. Units lost while the process stabilizes.

#### Total loss (min)

**Key:** total_loss

**Type:** number

**Expr:** breakdown + setup + minor + slow + defects + startup

#### OEE

**Key:** oee_row

**Type:** number

**Expr:** if(gt(planned, 0), (planned - total_loss) / planned * 100, 0)

**Format:** percent

**Rows:**

**Line:** Line 1 CNC cell

**Shift:** Day

**Planned:** 450

**Breakdown:** 28

**Setup:** 42

**Minor:** 24

**Slow:** 31

**Defects:** 12

**Startup:** 8

**Line:** Line 1 CNC cell

**Shift:** Evening

**Planned:** 450

**Breakdown:** 15

**Setup:** 55

**Minor:** 30

**Slow:** 36

**Defects:** 18

**Startup:** 6

**Line:** Line 2 SMT

**Shift:** Day

**Planned:** 450

**Breakdown:** 10

**Setup:** 38

**Minor:** 40

**Slow:** 22

**Defects:** 9

**Startup:** 12

**Line:** Line 2 SMT

**Shift:** Night

**Planned:** 450

**Breakdown:** 34

**Setup:** 20

**Minor:** 46

**Slow:** 28

**Defects:** 15

**Startup:** 5

**Line:** Packaging 3

**Shift:** Day

**Planned:** 450

**Breakdown:** 6

**Setup:** 25

**Minor:** 52

**Slow:** 40

**Defects:** 7

**Startup:** 4

**Totals:**

#### Total planned minutes

**Key:** planned

**Agg:** sum

**Format:** number

#### Total lost minutes

**Key:** total_loss

**Agg:** sum

**Format:** number

**Summary:**

#### OEE across all rows

**Key:** oee_all

**Expr:** if(gt(sum_planned, 0), (sum_planned - sum_total_loss) / sum_planned * 100, 0)

**Format:** percent

**Primary:** true

#### Equipment failure share of planned time

**Key:** breakdown_pct

**Expr:** if(gt(sum_planned, 0), sum_breakdown / sum_planned * 100, 0)

**Format:** percent

#### Setup and adjustment share

**Key:** setup_pct

**Expr:** if(gt(sum_planned, 0), sum_setup / sum_planned * 100, 0)

**Format:** percent

#### Idling and minor stops share

**Key:** minor_pct

**Expr:** if(gt(sum_planned, 0), sum_minor / sum_planned * 100, 0)

**Format:** percent

#### Reduced speed share

**Key:** slow_pct

**Expr:** if(gt(sum_planned, 0), sum_slow / sum_planned * 100, 0)

**Format:** percent

#### Process defects share

**Key:** defect_pct

**Expr:** if(gt(sum_planned, 0), sum_defects / sum_planned * 100, 0)

**Format:** percent

#### Startup rejects share

**Key:** startup_pct

**Expr:** if(gt(sum_planned, 0), sum_startup / sum_planned * 100, 0)

**Format:** percent

**Notes:** Convert quality losses to minutes by multiplying the number of defective units by the ideal cycle time in minutes. Time-based and speed losses are already minutes. Edit the example rows, add your own lines, then export to Excel for a Pareto chart.

## Content

**Intro:** The six big losses are the standard way to explain where OEE goes: two availability losses, two performance losses and two quality losses. This worksheet records each one in minutes per line and shift, calculates OEE for every row and shows what share of planned time each loss takes.

**Sections:**

#### How to use the worksheet

**Body:** Add one row per line and shift for the period you are studying. Enter planned production time, which is the shift minus planned breaks and planned maintenance. Then enter the minutes lost to each of the six categories. Stops and changeovers are measured directly. Slow running is the gap between the ideal cycle time and the actual one multiplied by units. Defects and startup rejects are units times ideal cycle time. The worksheet totals each row, computes OEE and summarizes each loss as a percent of all planned time. Export to Excel to rank the losses in a Pareto chart.

#### The six big losses explained

**Body:** The framework comes from total productive maintenance. Equipment failure and setup and adjustment reduce availability. Idling and minor stops and reduced speed reduce performance. Process defects and startup rejects reduce quality. Because every loss is in minutes, they add up neatly to the difference between planned time and fully productive time, so OEE is one minus the total loss over planned time. That view is easier to act on than three percentages because you can see which category is biggest and which line it comes from.

**Bullets:**

- Availability: equipment failure, setup and adjustment.
- Performance: idling and minor stops, reduced speed.
- Quality: process defects, startup rejects.

#### Reading the example

**Body:** The sample rows show a typical pattern: setup and minor stops are bigger than breakdowns, which surprises people who expect maintenance to dominate. Speed loss is often large because it is rarely measured. When you replace the sample with your own data, rank the six summary lines. The biggest line is where to send the first improvement team. Then look at the rows to find if the loss is spread across all lines or concentrated on one machine or shift, which changes the solution from standard work to a specific repair.

#### Common mistakes

**Body:** The usual problem is mixing planned and unplanned time. Breaks, planned maintenance and no-demand periods belong outside planned production time. Another is counting minor stops under a minimum length as speed loss in one plant and as stops in another, so write a rule, for example stops under five minutes are minor. Finally, do not double count: a unit scrapped at startup belongs in one category only. If your ERP or MES records reason codes, map each code to one of the six losses once and reuse the map.

**Cta:** If you want these losses pulled automatically from downtime reason codes and confirmations in your ERP or MES, Netray can build a read-only dashboard on your own data. The worksheet works without it.

**Faq:**

#### What are the six big losses?

**Answer:** Equipment failure, setup and adjustment, idling and minor stops, reduced speed, process defects and startup rejects. They come from total productive maintenance and cover every way OEE can fall below 100 percent.

#### How do I convert defects to minutes?

**Answer:** Multiply the number of scrapped or reworked units by the ideal cycle time per unit in minutes. That gives the production time spent on parts that did not count as good, so it can be added to the time based losses.

#### Why does the worksheet use planned production time?

**Answer:** OEE measures how well you ran when you planned to run. Planned breaks and scheduled maintenance are excluded so they do not count as losses. Use TEEP if you want to include unscheduled time as well.

#### Can I use it for a whole plant?

**Answer:** Yes, add a row for each line and shift. The summary lines then show plant level shares. Look at the rows too, because a plant average can hide one machine with a severe breakdown problem.

## Search terms

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