OEE Diagnosis Workbook: Interactive Loss Capture & Experiment Planner

{ "Title": "OEE Diagnosis Workbook", "IntroductionHtml": "

Use this workbook to diagnose your biggest OEE losses and run short, operator-centred experiments that produce measurable gains.

This interactive form guides a frontline team through reliable measurement, shift-by-shift loss capture, root-cause drill-down for the top three losses, an experiment canvas, verification & sustainment checks, and a simple 30/60/90 results tracker.

How to use it: Fill the Measurement section for a representative shift or period. Use the Loss Capture entries to record the most important events during a shift (repeat daily or per shift). Complete the Root-Cause and Experiment sections for your top 1–3 losses. Save the form each time you complete an experiment cycle; submissions are stored so teams can compare results over time.

Key formulas (for manual calculation):

• Availability % = (Planned Production Time - Unplanned Stop Time) / Planned Production Time × 100
• Performance % = (Ideal Cycle Time × Total Count) / Net Run Time × 100
• Quality % = Good Count / Total Count × 100
• OEE % = Availability × Performance × Quality (expressed as percentages, multiply as fractions)

If you'd like automatic calculations, consider enabling a connected OEE dashboard or adding calculated fields via platform enhancements (see Capability Notes).

", "SubmitLabel": "Save Workbook Entry", "SuccessMessage": "Workbook saved. Return anytime to update losses, experiments, and results.", "DataType": "OEEWorkbookSubmission", "SchemaVersion": "1.0", "Fields": [ { "Key": "entry_date", "Label": "Entry date", "FieldType": "text", "HelpText": "Date and shift (e.g., 2026-08-27, Shift A).", "Required": true }, { "Key": "location_or_line", "Label": "Location / Line / Cell", "FieldType": "text", "HelpText": "Where this measurement was taken (plant, line, cell).", "Required": true }, { "Key": "operator_or_supervisor", "Label": "Operator / Supervisor", "FieldType": "text", "HelpText": "Name or role of the person reporting.", "Required": false }, {"Key":"measurement_section_header","Label":"Measurement & Key Inputs","FieldType":"text","HelpText":"Fill these numbers for the period or shift you are diagnosing.","Required":false}, { "Key": "planned_production_time_min", "Label": "Planned production time (minutes)", "FieldType": "number", "HelpText": "Total scheduled production time for the shift/period (exclude planned breaks).", "Required": true }, { "Key": "unplanned_stop_time_min", "Label": "Unplanned stop time (minutes)", "FieldType": "number", "HelpText": "Total minutes lost to unplanned stops during the period.", "Required": true }, { "Key": "ideal_cycle_time_sec", "Label": "Ideal cycle time (seconds)", "FieldType": "number", "HelpText": "Manufacturer or target cycle time per good part.", "Required": true }, { "Key": "total_count", "Label": "Total produced (count)", "FieldType": "number", "HelpText": "Total number of parts started/produced in the period.", "Required": true }, { "Key": "good_count", "Label": "Good parts (count)", "FieldType": "number", "HelpText": "Count of parts meeting quality acceptance.", "Required": true }, { "Key": "availability_pct", "Label": "Availability (%) — optional manual entry", "FieldType": "number", "HelpText": "Enter calculated availability if you compute it offline. Formula in the intro.", "Required": false }, { "Key": "performance_pct", "Label": "Performance (%) — optional manual entry", "FieldType": "number", "HelpText": "Enter calculated performance if you compute it offline.", "Required": false }, { "Key": "quality_pct", "Label": "Quality (%) — optional manual entry", "FieldType": "number", "HelpText": "Enter calculated quality if you compute it offline.", "Required": false }, { "Key": "oee_pct", "Label": "OEE (%) — optional manual entry", "FieldType": "number", "HelpText": "Enter overall OEE if you compute it.", "Required": false }, {"Key":"loss_capture_header","Label":"Loss capture (record the most important events during the shift)","FieldType":"text","HelpText":"Use one row per loss event. The form provides multiple slots — add the top 6 losses for this period.","Required":false}, { "Key": "loss_1_category", "Label": "Loss 1 — Category", "FieldType": "select", "HelpText": "Choose the primary loss category.", "Required": false, "Options": [ {"Value": "equipment_failure", "Label": "Equipment failure"}, {"Value": "changeover_setup", "Label": "Changeover / setup"}, {"Value": "idling_minor_stops", "Label": "Idling & minor stops"}, {"Value": "rework_scrap", "Label": "Rework / scrap"}, {"Value": "reduced_speed", "Label": "Reduced speed"}, {"Value": "material_shortage", "Label": "Material shortage"}, {"Value": "operator_error", "Label": "Operator / process error"}, {"Value": "other", "Label": "Other"} ] }, { "Key": "loss_1_duration_min", "Label": "Loss 1 — Duration (minutes)", "FieldType": "number", "HelpText": "Total minutes for this loss event (or aggregated for similar events).", "Required": false }, { "Key": "loss_1_count", "Label": "Loss 1 — Count (if applicable)", "FieldType": "number", "HelpText": "Number of occurrences or defective parts related to this loss.", "Required": false }, { "Key": "loss_1_brief", "Label": "Loss 1 — Brief description", "FieldType": "textarea", "HelpText": "Short description of what happened.", "Required": false }, { "Key": "loss_2_category", "Label": "Loss 2 — Category", "FieldType": "select", "Options": [ {"Value": "equipment_failure", "Label": "Equipment failure"}, {"Value": "changeover_setup", "Label": "Changeover / setup"}, {"Value": "idling_minor_stops", "Label": "Idling & minor stops"}, {"Value": "rework_scrap", "Label": "Rework / scrap"}, {"Value": "reduced_speed", "Label": "Reduced speed"}, {"Value": "material_shortage", "Label": "Material shortage"}, {"Value": "operator_error", "Label": "Operator / process error"}, {"Value": "other", "Label": "Other"} ], "Required": false }, { "Key": "loss_2_duration_min", "Label": "Loss 2 — Duration (minutes)", "FieldType": "number", "Required": false }, {"Key":"loss_2_count","Label":"Loss 2 — Count (if applicable)","FieldType":"number","Required":false}, {"Key":"loss_2_brief","Label":"Loss 2 — Brief description","FieldType":"textarea","Required":false}, { "Key": "loss_3_category", "Label": "Loss 3 — Category", "FieldType": "select", "Options": [ {"Value": "equipment_failure", "Label": "Equipment failure"}, {"Value": "changeover_setup", "Label": "Changeover / setup"}, {"Value": "idling_minor_stops", "Label": "Idling & minor stops"}, {"Value": "rework_scrap", "Label": "Rework / scrap"}, {"Value": "reduced_speed", "Label": "Reduced speed"}, {"Value": "material_shortage", "Label": "Material shortage"}, {"Value": "operator_error", "Label": "Operator / process error"}, {"Value": "other", "Label": "Other"} ], "Required": false }, {"Key":"loss_3_duration_min","Label":"Loss 3 — Duration (minutes)","FieldType":"number","Required":false}, {"Key":"loss_3_count","Label":"Loss 3 — Count (if applicable)","FieldType":"number","Required":false}, {"Key":"loss_3_brief","Label":"Loss 3 — Brief description","FieldType":"textarea","Required":false}, { "Key": "loss_4_category", "Label": "Loss 4 — Category (optional)", "FieldType": "select", "Options": [ {"Value": "equipment_failure", "Label": "Equipment failure"}, {"Value": "changeover_setup", "Label": "Changeover / setup"}, {"Value": "idling_minor_stops", "Label": "Idling & minor stops"}, {"Value": "rework_scrap", "Label": "Rework / scrap"}, {"Value": "reduced_speed", "Label": "Reduced speed"}, {"Value": "material_shortage", "Label": "Material shortage"}, {"Value": "operator_error", "Label": "Operator / process error"}, {"Value": "other", "Label": "Other"} ], "Required": false }, {"Key":"loss_4_duration_min","Label":"Loss 4 — Duration (minutes)","FieldType":"number","Required":false}, {"Key":"loss_4_count","Label":"Loss 4 — Count (if applicable)","FieldType":"number","Required":false}, {"Key":"loss_4_brief","Label":"Loss 4 — Brief description","FieldType":"textarea","Required":false}, {"Key":"loss_5_category","Label":"Loss 5 — Category (optional)","FieldType":"select","Options":[{"Value":"equipment_failure","Label":"Equipment failure"},{"Value":"changeover_setup","Label":"Changeover / setup"},{"Value":"idling_minor_stops","Label":"Idling & minor stops"},{"Value":"rework_scrap","Label":"Rework / scrap"},{"Value":"reduced_speed","Label":"Reduced speed"},{"Value":"material_shortage","Label":"Material shortage"},{"Value":"operator_error","Label":"Operator / process error"},{"Value":"other","Label":"Other"}],"Required":false}, {"Key":"loss_5_duration_min","Label":"Loss 5 — Duration (minutes)","FieldType":"number","Required":false}, {"Key":"loss_5_count","Label":"Loss 5 — Count (if applicable)","FieldType":"number","Required":false}, {"Key":"loss_5_brief","Label":"Loss 5 — Brief description","FieldType":"textarea","Required":false}, {"Key":"loss_6_category","Label":"Loss 6 — Category (optional)","FieldType":"select","Options":[{"Value":"equipment_failure","Label":"Equipment failure"},{"Value":"changeover_setup","Label":"Changeover / setup"},{"Value":"idling_minor_stops","Label":"Idling & minor stops"},{"Value":"rework_scrap","Label":"Rework / scrap"},{"Value":"reduced_speed","Label":"Reduced speed"},{"Value":"material_shortage","Label":"Material shortage"},{"Value":"operator_error","Label":"Operator / process error"},{"Value":"other","Label":"Other"}],"Required":false}, {"Key":"loss_6_duration_min","Label":"Loss 6 — Duration (minutes)","FieldType":"number","Required":false}, {"Key":"loss_6_count","Label":"Loss 6 — Count (if applicable)","FieldType":"number","Required":false}, {"Key":"loss_6_brief","Label":"Loss 6 — Brief description","FieldType":"textarea","Required":false}, {"Key":"root_cause_header","Label":"Root-cause drill-down (Top 3 losses)","FieldType":"text","HelpText":"For each top loss, work through root causes and specify owner and target dates.","Required":false}, {"Key":"top1_loss_name","Label":"Top loss #1 — Short name","FieldType":"text","HelpText":"Short label (e.g., 'Hydraulic pump failure').","Required":false}, {"Key":"top1_5whys","Label":"Top loss #1 — 5-Why / immediate causes","FieldType":"textarea","HelpText":"Write a concise 5-why chain or key contributing causes.","Required":false}, {"Key":"top1_contributing_factors","Label":"Top loss #1 — Contributing factors","FieldType":"textarea","HelpText":"People, parts, process, environment, tools, data, training, documentation.","Required":false}, {"Key":"top1_countermeasure_ideas","Label":"Top loss #1 — Countermeasure ideas","FieldType":"textarea","HelpText":"Shortlist practical fixes to test.","Required":false}, {"Key":"top1_countermeasure_owner","Label":"Top loss #1 — Owner (who will run the experiment)","FieldType":"text","Required":false}, {"Key":"top1_target_date_days","Label":"Top loss #1 — Target timebox (days)","FieldType":"number","HelpText":"Time to run the first experiment trial (e.g., 7).","Required":false}, {"Key":"top2_loss_name","Label":"Top loss #2 — Short name","FieldType":"text","Required":false}, {"Key":"top2_5whys","Label":"Top loss #2 — 5-Why / immediate causes","FieldType":"textarea","Required":false}, {"Key":"top2_contributing_factors","Label":"Top loss #2 — Contributing factors","FieldType":"textarea","Required":false}, {"Key":"top2_countermeasure_ideas","Label":"Top loss #2 — Countermeasure ideas","FieldType":"textarea","Required":false}, {"Key":"top2_countermeasure_owner","Label":"Top loss #2 — Owner","FieldType":"text","Required":false}, {"Key":"top2_target_date_days","Label":"Top loss #2 — Target timebox (days)","FieldType":"number","Required":false}, {"Key":"top3_loss_name","Label":"Top loss #3 — Short name","FieldType":"text","Required":false}, {"Key":"top3_5whys","Label":"Top loss #3 — 5-Why / immediate causes","FieldType":"textarea","Required":false}, {"Key":"top3_contributing_factors","Label":"Top loss #3 — Contributing factors","FieldType":"textarea","Required":false}, {"Key":"top3_countermeasure_ideas","Label":"Top loss #3 — Countermeasure ideas","FieldType":"textarea","Required":false}, {"Key":"top3_countermeasure_owner","Label":"Top loss #3 — Owner","FieldType":"text","Required":false}, {"Key":"top3_target_date_days","Label":"Top loss #3 — Target timebox (days)","FieldType":"number","Required":false}, {"Key":"experiment_header","Label":"Rapid experiment canvas","FieldType":"text","HelpText":"Design short, testable experiments for your top countermeasures.","Required":false}, {"Key":"experiment_title","Label":"Experiment title","FieldType":"text","HelpText":"Short name for the experiment.","Required":false}, {"Key":"experiment_hypothesis","Label":"Hypothesis (if we ___ then ___ because ___)","FieldType":"textarea","HelpText":"Make the expected cause-effect clear and measurable.","Required":false}, {"Key":"experiment_owner","Label":"Experiment owner","FieldType":"text","Required":false}, {"Key":"experiment_timebox_days","Label":"Experiment timebox (days)","FieldType":"number","HelpText":"Short, timeboxed trial length (e.g., 7).","Required":false}, {"Key":"experiment_expected_oee_gain_pct","Label":"Expected OEE gain (absolute % points)","FieldType":"number","HelpText":"Example: 3 (meaning +3 percentage points).","Required":false}, {"Key":"experiment_success_criteria","Label":"Success criteria (how we'll know it worked)","FieldType":"textarea","HelpText":"Be specific and measurable.","Required":false}, {"Key":"experiment_required_resources","Label":"Required resources & safety/quality notes","FieldType":"textarea","HelpText":"People, spares, tools, and any safety/quality mitigations.","Required":false}, {"Key":"verification_header","Label":"Verification & sustainment checklist","FieldType":"text","HelpText":"Use this checklist after an experiment shows positive results.","Required":false}, {"Key":"vcp_data_collection_updated","Label":"Data collection rules updated (e.g., shift log, stop codes)","FieldType":"yesno","HelpText":"Have data capture templates, stop codes, and owners been updated?","Required":false}, {"Key":"vcp_standard_work_updated","Label":"Standard work / checklists updated","FieldType":"yesno","HelpText":"Is there an updated standard operating procedure?","Required":false}, {"Key":"vcp_training_done","Label":"Training / handover completed","FieldType":"yesno","HelpText":"Have impacted operators been trained?","Required":false}, {"Key":"vcp_control_plan", "Label":"Control plan / visual management in place", "FieldType":"yesno", "HelpText":"Are controls and monitoring in place to sustain the gain?", "Required":false }, {"Key":"vcp_owner","Label":"Sustainment owner","FieldType":"text","HelpText":"Who owns long-term sustainment?", "Required":false}, {"Key":"vcp_review_date","Label":"Review date (e.g., 30 days)","FieldType":"text","HelpText":"When will the sustainment be reviewed?", "Required":false}, {"Key":"tracking_header","Label":"30 / 60 / 90 day tracking","FieldType":"text","HelpText":"Record OEE or component results to see if gains hold.","Required":false}, {"Key":"baseline_oee_pct","Label":"Baseline OEE (%)","FieldType":"number","HelpText":"OEE before the experiment.","Required":false}, {"Key":"oee_30_pct","Label":"OEE @ 30 days (%)","FieldType":"number","Required":false}, {"Key":"oee_60_pct","Label":"OEE @ 60 days (%)","FieldType":"number","Required":false}, {"Key":"oee_90_pct","Label":"OEE @ 90 days (%)","FieldType":"number","Required":false}, {"Key":"results_notes","Label":"Results & notes","FieldType":"textarea","HelpText":"Observations, unexpected consequences, lessons learned.","Required":false}, {"Key":"next_steps","Label":"Next steps / backlog items","FieldType":"textarea","HelpText":"What to do next and who will do it.","Required":false} ] }