Run Rate and Cycle Time Study Worksheet
The performance factor in OEE depends on a standard cycle time that is only as good as its last check. This worksheet records timed cycles for each part, compares them with the standard, and shows the speed percentage that explains where performance loss is hiding.
| Part or job | Machine | Cycle 1 (s) | Cycle 2 (s) | Cycle 3 (s) | Standard cycle (s) | Average cycle (s) | Best cycle (s) | Actual rate per hour | Speed vs standard | |
|---|---|---|---|---|---|---|---|---|---|---|
48.6667 | 47 | 73.9726 | 92.5% | |||||||
133.3333 | 128 | 27 | 90% | |||||||
6.3333 | 6.1 | 568.4211 | 94.7% | |||||||
72 | 70 | 50 | 104.2% |
Time at least three consecutive cycles under normal conditions with the usual operator, excluding stops. A speed above one hundred percent means the standard is out of date, which is as important to fix as a slow machine.
Check routing standards against actuals
Optional: we can review how your ERP routing times compare with real machine cycles and suggest a regular check.
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How to use the study sheet
Pick a part and machine, stand at the machine with a stopwatch or a video, and record three consecutive cycles in seconds. Enter the standard cycle from your routing or ERP. The worksheet calculates the average and best cycle, the actual parts per hour, and speed versus standard. Repeat for the top ten parts by volume. Do the study on all shifts, since cycles often differ between crews, and note the operator and conditions in the part field when they are unusual.
Standard, ideal and best demonstrated
OEE uses an ideal cycle time, the fastest rate the machine can run continuously at good quality. Routings often carry a slower planning standard with allowances. If the ideal is set too slow, OEE can exceed one hundred percent and hide real losses. If it is set too fast, the team sees permanent performance loss that cannot be fixed. The best-cycle column helps you judge what the machine has actually demonstrated.
- Ideal rate: used for the OEE performance factor
- Routing standard: used for scheduling and costing
- Best demonstrated: a reality check for both
Interpreting speed percent
A value of ninety percent means the machine takes about eleven percent longer than the standard. Speed losses come from worn tooling, conservative feeds, material variation, operator hesitation or limits set to avoid defects. A large spread between the best and average cycle indicates inconsistency, which is a different problem from uniformly slow running. Where the actual rate is faster than standard, update the standard in your ERP routing so capacity planning is realistic.
Common mistakes
Timing only the first cycle after a start usually overstates the cycle time because of warm up. Including operator breaks inflates the number and double counts stops that belong in the downtime log. Avoid studying only the best operator, or only the worst job. Also remember that one set of three cycles is a sample, not a proof, so repeat the study before changing a standard.
Frequently Asked Questions
How many cycles should I time?
Three consecutive cycles is a quick check; ten or more gives a stronger sample for changing a standard. The worksheet takes three per row, so enter several rows for the same part on different shifts if you want a larger sample.
Why does OEE exceed 100 percent sometimes?
Almost always because the ideal cycle time is slower than what the machine really achieves. Fix the standard, not the formula. Once the ideal reflects the fastest sustainable rate, OEE stays at or below one hundred percent.
Should I include allowances in the standard?
For the OEE ideal cycle, no. Allowances for fatigue or minor delays belong in scheduling standards. Including them in the ideal hides losses and lowers the ceiling you are measuring against.
Can I export the data?
Yes. Export to Excel, CSV or PDF from the page. All calculations happen in your browser and nothing is sent to a server.
If your routing standards sit in an ERP and actual cycles are captured by the machine, we can compare them automatically and flag standards that have drifted.
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