Packaging Line Downtime and OEE Log Worksheet
Packaging lines lose output in many small stops that nobody records. This worksheet turns a shift's basic counts into availability, performance, quality and OEE, so the biggest loss category becomes visible.
| Shift / date | Line | Planned production time (min) | Downtime (min) | Ideal rate (units/min) | Total units produced | Rejects (units) | Availability % | Performance % | Quality % | OEE % | |
|---|---|---|---|---|---|---|---|---|---|---|---|
86.2% | 91.3% | 98.9% | 77.8% | ||||||||
91.6% | 94.7% | 99.3% | 86.1% | ||||||||
81.1% | 90.4% | 99.6% | 73% | ||||||||
94.4% | 92.9% | 98.9% | 86.8% | ||||||||
87.8% | 92.8% | 99.7% | 81.2% |
OEE here is availability x performance x quality, with performance capped at 100%. Use the line's ideal (nameplate or demonstrated best) rate, not a rate lowered to hide losses. Planned stops such as breaks should be excluded from planned production time according to your own OEE policy.
Automate OEE from your ERP and machines
Optional: a short review of how to calculate OEE from live counts and ERP production orders.
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How to use the worksheet
Add a row per line per shift. Enter planned production time, total downtime minutes, the ideal rate in units per minute, total units produced and rejects. The sheet computes the three OEE factors and the combined figure. Export to Excel to trend by week or to add a loss reason column.
The OEE formulas
Availability is run time divided by planned time. Performance is total units divided by run time times ideal rate. Quality is good units divided by total units. OEE is the product of the three. Because the three factors multiply, a line at 90 percent on each factor is at about 73 percent overall, which surprises many teams.
- Availability loses time to breakdowns, changeovers and waiting for material
- Performance loses speed to micro-stops and reduced rates
- Quality loses units to rejects and rework
Reading results honestly
OEE figures are only useful when the ideal rate and the planned time rules are fixed and shared. Compare a line with its own history. Avoid comparing different line types, since a cartoner and a wrapper have very different loss patterns. Start with the lowest of the three factors, because that is where improvement is cheapest.
Frequently Asked Questions
What is a good OEE for a packaging line?
It depends on the line type and product mix. Many plants see 50 to 70 percent on lines with frequent changeovers. Use your own baseline and improve against it. Comparing against a generic world-class number is often misleading.
Should changeover time count as downtime?
Most plants count it as availability loss because the line is not producing, and then track it separately. If you plan changeovers out of planned production time, document that rule and apply it consistently.
Why is performance capped at 100 percent?
If a line exceeds the ideal rate, the ideal rate was set too low. Capping prevents performance above 100 percent from masking availability or quality losses. Update the ideal rate instead.
How do I handle several products on one shift?
Add one row per product run with its own ideal rate and planned time. The average OEE in the totals is a simple average of rows, so weight by time in Excel if run lengths differ much.
If you want OEE calculated automatically from machine counters and posted against production orders, we can review how to feed it from your MES or ERP.
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