OEE Top-Loss Diagnosis Workbook

{"Title":"OEE Top-Loss Diagnosis Workbook","IntroductionHtml":"

Purpose

This interactive workbook helps frontline teams quickly identify, quantify, and prioritize the top Availability, Performance, and Quality losses affecting your OEE. Use it to capture the facts, run a lightweight 5‑Whys for each top loss, propose and plan small experiments, and record the success metrics and sustainment steps that keep improvements in place.

How to use

1. Complete the data intake for the line, shift and date range you are diagnosing.
2. Enter up to five candidate losses (start with the ones that feel biggest).
3. Estimate minutes lost and frequency so you can rank by impact; rank losses from 1 (highest priority) to 5 (lowest).
4. For each top loss, run a short 5‑Whys, capture a hypothesis, and plan a small experiment you can try within a shift or two.
5. Save the workbook, assign owners, run the experiment, record results, and use the sustainment checklist to lock in the gain.

Tip: If you have a continuous data source (MES/MES/OEE tool), use these fields to record the measured values and references so the team can later verify results.

","SubmitLabel":"Save Workbook","SuccessMessage":"Workbook saved. You can return to update entries, run follow-ups, or export the data for reports.","DataType":"oee-top-loss-workbook","SchemaVersion":"1.0","Fields":[{"Key":"plant","Type":"text","Label":"Plant / Site","HelpText":"Enter plant or site name (e.g., Plant A).","Required":false},{"Key":"area_or_line","Type":"text","Label":"Area / Line / Cell","HelpText":"Where these losses are occurring (line name or number).","Required":true},{"Key":"shift","Type":"select","Label":"Shift","HelpText":"Which shift is being diagnosed.","Required":false,"Options":[{"Value":"1","Label":"Shift 1"},{"Value":"2","Label":"Shift 2"},{"Value":"3","Label":"Shift 3"},{"Value":"all","Label":"All / Multi-shift"}]},{"Key":"date_range","Type":"text","Label":"Date range or diagnosis date","HelpText":"Specify the date range or single date for this analysis (e.g., 2026-08-01 to 2026-08-07).","Required":true},{"Key":"data_source","Type":"text","Label":"Primary data source","HelpText":"Where OEE / downtime numbers came from (MES, manual log, supervisor report).","Required":false},{"Key":"notes_context","Type":"textarea","Label":"Context / Quick notes","HelpText":"Short context for the team (product mix, recent changes, known issues).","Required":false},{"Key":"instructions_ranking","Type":"textarea","Label":"Loss ranking instructions","HelpText":"To prioritize, estimate impact = (minutes lost per event × events per period) or use your best available measure. Enter ranks 1 (highest) to 5 (lowest).","Required":false},{"Key":"loss_1_name","Type":"text","Label":"Loss 1 — name or short description","HelpText":"Describe the observed loss (e.g., Machine warm-up delay, sensor faults, scrap at operation X).","Required":false},{"Key":"loss_1_minutes_lost","Type":"number","Label":"Loss 1 — estimated minutes lost per occurrence","HelpText":"Estimate minutes lost each time this loss happens.","Required":false},{"Key":"loss_1_frequency","Type":"number","Label":"Loss 1 — estimated occurrences per week","HelpText":"How often this typically occurs in a week.","Required":false},{"Key":"loss_1_category","Type":"select","Label":"Loss 1 — primary category","HelpText":"Choose the main category that best fits the loss.","Required":false,"Options":[{"Value":"equipment","Label":"Equipment"},{"Value":"process","Label":"Process"},{"Value":"material","Label":"Material"},{"Value":"human","Label":"Human / training"},{"Value":"planning","Label":"Planning / scheduling"},{"Value":"tooling","Label":"Tooling / fixture"},{"Value":"environment","Label":"Environment / utilities"},{"Value":"data_systems","Label":"Data / systems"},{"Value":"other","Label":"Other"}]},{"Key":"loss_1_rank","Type":"select","Label":"Loss 1 — priority rank","HelpText":"Assign a rank where 1 = highest priority (use unique ranks where possible).","Required":false,"Options":[{"Value":"1","Label":"1 (highest)"},{"Value":"2","Label":"2"},{"Value":"3","Label":"3"},{"Value":"4","Label":"4"},{"Value":"5","Label":"5 (lowest)"}]},{"Key":"loss_1_root_brief","Type":"textarea","Label":"Loss 1 — observed immediate cause","HelpText":"Briefly describe the immediate cause you observed.","Required":false},{"Key":"loss_1_why_1","Type":"textarea","Label":"Loss 1 — Why #1","HelpText":"Why did this happen? (first answer)","Required":false},{"Key":"loss_1_why_2","Type":"textarea","Label":"Loss 1 — Why #2","HelpText":"Ask why again; build on prior answer.","Required":false},{"Key":"loss_1_why_3","Type":"textarea","Label":"Loss 1 — Why #3","HelpText":"Third why. Keep going until root cause feels actionable.","Required":false},{"Key":"loss_1_why_4","Type":"textarea","Label":"Loss 1 — Why #4","HelpText":"Fourth why.","Required":false},{"Key":"loss_1_why_5","Type":"textarea","Label":"Loss 1 — Why #5","HelpText":"Fifth why — capture the likely root cause.","Required":false},{"Key":"loss_1_experiment_hypothesis","Type":"textarea","Label":"Loss 1 — experiment hypothesis","HelpText":"Short hypothesis: if we [change / fix], then [expected measurable outcome].","Required":false},{"Key":"loss_1_small_experiment_plan","Type":"textarea","Label":"Loss 1 — small experiment plan","HelpText":"Plan a small, time-boxed test (who, what, where, how long, data to collect). Keep it low-cost and reversible.","Required":false},{"Key":"loss_1_success_metrics","Type":"textarea","Label":"Loss 1 — success metrics","HelpText":"How will you know the experiment worked? (e.g., reduce minutes lost per occurrence from X to Y, reduce frequency from A to B). Include measurement method and sample period.","Required":false},{"Key":"loss_1_owner","Type":"text","Label":"Loss 1 — owner for experiment","HelpText":"Who will run the experiment and collect results?","Required":false},{"Key":"loss_1_target_date","Type":"text","Label":"Loss 1 — target completion date","HelpText":"Target date for experiment or evaluation (YYYY-MM-DD).","Required":false},{"Key":"loss_1_sustain_actions","Type":"textarea","Label":"Loss 1 — sustainment actions","HelpText":"Actions to lock in the improvement if the experiment succeeds (training, standard work, poka-yoke, spare parts, schedule change).","Required":false},{"Key":"loss_2_name","Type":"text","Label":"Loss 2 — name or short description","HelpText":"(Optional) Enter another loss to analyze.","Required":false},{"Key":"loss_2_minutes_lost","Type":"number","Label":"Loss 2 — estimated minutes lost per occurrence","HelpText":"","Required":false},{"Key":"loss_2_frequency","Type":"number","Label":"Loss 2 — estimated occurrences per week","HelpText":"","Required":false},{"Key":"loss_2_category","Type":"select","Label":"Loss 2 — primary category","HelpText":"","Required":false,"Options":[{"Value":"equipment","Label":"Equipment"},{"Value":"process","Label":"Process"},{"Value":"material","Label":"Material"},{"Value":"human","Label":"Human / training"},{"Value":"planning","Label":"Planning / scheduling"},{"Value":"tooling","Label":"Tooling / fixture"},{"Value":"environment","Label":"Environment / utilities"},{"Value":"data_systems","Label":"Data / systems"},{"Value":"other","Label":"Other"}]},{"Key":"loss_2_rank","Type":"select","Label":"Loss 2 — priority rank","HelpText":"","Required":false,"Options":[{"Value":"1","Label":"1 (highest)"},{"Value":"2","Label":"2"},{"Value":"3","Label":"3"},{"Value":"4","Label":"4"},{"Value":"5","Label":"5 (lowest)"}]},{"Key":"loss_2_root_brief","Type":"textarea","Label":"Loss 2 — observed immediate cause","HelpText":"","Required":false},{"Key":"loss_2_why_1","Type":"textarea","Label":"Loss 2 — Why #1","HelpText":"","Required":false},{"Key":"loss_2_why_2","Type":"textarea","Label":"Loss 2 — Why #2","HelpText":"","Required":false},{"Key":"loss_2_why_3","Type":"textarea","Label":"Loss 2 — Why #3","HelpText":"","Required":false},{"Key":"loss_2_why_4","Type":"textarea","Label":"Loss 2 — Why #4","HelpText":"","Required":false},{"Key":"loss_2_why_5","Type":"textarea","Label":"Loss 2 — Why #5","HelpText":"","Required":false},{"Key":"loss_2_experiment_hypothesis","Type":"textarea","Label":"Loss 2 — experiment hypothesis","HelpText":"","Required":false},{"Key":"loss_2_small_experiment_plan","Type":"textarea","Label":"Loss 2 — small experiment plan","HelpText":"","Required":false},{"Key":"loss_2_success_metrics","Type":"textarea","Label":"Loss 2 — success metrics","HelpText":"","Required":false},{"Key":"loss_2_owner","Type":"text","Label":"Loss 2 — owner for experiment","HelpText":"","Required":false},{"Key":"loss_2_target_date","Type":"text","Label":"Loss 2 — target completion date","HelpText":"","Required":false},{"Key":"loss_2_sustain_actions","Type":"textarea","Label":"Loss 2 — sustainment actions","HelpText":"","Required":false},{"Key":"loss_3_name","Type":"text","Label":"Loss 3 — name or short description","HelpText":"(Optional)","Required":false},{"Key":"loss_3_minutes_lost","Type":"number","Label":"Loss 3 — estimated minutes lost per occurrence","HelpText":"","Required":false},{"Key":"loss_3_frequency","Type":"number","Label":"Loss 3 — estimated occurrences per week","HelpText":"","Required":false},{"Key":"loss_3_category","Type":"select","Label":"Loss 3 — primary category","HelpText":"","Required":false,"Options":[{"Value":"equipment","Label":"Equipment"},{"Value":"process","Label":"Process"},{"Value":"material","Label":"Material"},{"Value":"human","Label":"Human / training"},{"Value":"planning","Label":"Planning / scheduling"},{"Value":"tooling","Label":"Tooling / fixture"},{"Value":"environment","Label":"Environment / utilities"},{"Value":"data_systems","Label":"Data / systems"},{"Value":"other","Label":"Other"}]},{"Key":"loss_3_rank","Type":"select","Label":"Loss 3 — priority rank","HelpText":"","Required":false,"Options":[{"Value":"1","Label":"1 (highest)"},{"Value":"2","Label":"2"},{"Value":"3","Label":"3"},{"Value":"4","Label":"4"},{"Value":"5","Label":"5 (lowest)"}]},{"Key":"loss_3_root_brief","Type":"textarea","Label":"Loss 3 — observed immediate cause","HelpText":"","Required":false},{"Key":"loss_3_why_1","Type":"textarea","Label":"Loss 3 — Why #1","HelpText":"","Required":false},{"Key":"loss_3_why_2","Type":"textarea","Label":"Loss 3 — Why #2","HelpText":"","Required":false},{"Key":"loss_3_why_3","Type":"textarea","Label":"Loss 3 — Why #3","HelpText":"","Required":false},{"Key":"loss_3_why_4","Type":"textarea","Label":"Loss 3 — Why #4","HelpText":"","Required":false},{"Key":"loss_3_why_5","Type":"textarea","Label":"Loss 3 — Why #5","HelpText":"","Required":false},{"Key":"loss_3_experiment_hypothesis","Type":"textarea","Label":"Loss 3 — experiment hypothesis","HelpText":"","Required":false},{"Key":"loss_3_small_experiment_plan","Type":"textarea","Label":"Loss 3 — small experiment plan","HelpText":"","Required":false},{"Key":"loss_3_success_metrics","Type":"textarea","Label":"Loss 3 — success metrics","HelpText":"","Required":false},{"Key":"loss_3_owner","Type":"text","Label":"Loss 3 — owner for experiment","HelpText":"","Required":false},{"Key":"loss_3_target_date","Type":"text","Label":"Loss 3 — target completion date","HelpText":"","Required":false},{"Key":"loss_3_sustain_actions","Type":"textarea","Label":"Loss 3 — sustainment actions","HelpText":"","Required":false},{"Key":"loss_4_name","Type":"text","Label":"Loss 4 — name or short description","HelpText":"(Optional)","Required":false},{"Key":"loss_4_minutes_lost","Type":"number","Label":"Loss 4 — estimated minutes lost per occurrence","HelpText":"","Required":false},{"Key":"loss_4_frequency","Type":"number","Label":"Loss 4 — estimated occurrences per week","HelpText":"","Required":false},{"Key":"loss_4_category","Type":"select","Label":"Loss 4 — primary category","HelpText":"","Required":false,"Options":[{"Value":"equipment","Label":"Equipment"},{"Value":"process","Label":"Process"},{"Value":"material","Label":"Material"},{"Value":"human","Label":"Human / training"},{"Value":"planning","Label":"Planning / scheduling"},{"Value":"tooling","Label":"Tooling / fixture"},{"Value":"environment","Label":"Environment / utilities"},{"Value":"data_systems","Label":"Data / systems"},{"Value":"other","Label":"Other"}]},{"Key":"loss_4_rank","Type":"select","Label":"Loss 4 — priority rank","HelpText":"","Required":false,"Options":[{"Value":"1","Label":"1 (highest)"},{"Value":"2","Label":"2"},{"Value":"3","Label":"3"},{"Value":"4","Label":"4"},{"Value":"5","Label":"5 (lowest)"}]},{"Key":"loss_4_root_brief","Type":"textarea","Label":"Loss 4 — observed immediate cause","HelpText":"","Required":false},{"Key":"loss_4_why_1","Type":"textarea","Label":"Loss 4 — Why #1","HelpText":"","Required":false},{"Key":"loss_4_why_2","Type":"textarea","Label":"Loss 4 — Why #2","HelpText":"","Required":false},{"Key":"loss_4_why_3","Type":"textarea","Label":"Loss 4 — Why #3","HelpText":"","Required":false},{"Key":"loss_4_why_4","Type":"textarea","Label":"Loss 4 — Why #4","HelpText":"","Required":false},{"Key":"loss_4_why_5","Type":"textarea","Label":"Loss 4 — Why #5","HelpText":"","Required":false},{"Key":"loss_4_experiment_hypothesis","Type":"textarea","Label":"Loss 4 — experiment hypothesis","HelpText":"","Required":false},{"Key":"loss_4_small_experiment_plan","Type":"textarea","Label":"Loss 4 — small experiment plan","HelpText":"","Required":false},{"Key":"loss_4_success_metrics","Type":"textarea","Label":"Loss 4 — success metrics","HelpText":"","Required":false},{"Key":"loss_4_owner","Type":"text","Label":"Loss 4 — owner for experiment","HelpText":"","Required":false},{"Key":"loss_4_target_date","Type":"text","Label":"Loss 4 — target completion date","HelpText":"","Required":false},{"Key":"loss_4_sustain_actions","Type":"textarea","Label":"Loss 4 — sustainment actions","HelpText":"","Required":false},{"Key":"loss_5_name","Type":"text","Label":"Loss 5 — name or short description","HelpText":"(Optional)","Required":false},{"Key":"loss_5_minutes_lost","Type":"number","Label":"Loss 5 — estimated minutes lost per occurrence","HelpText":"","Required":false},{"Key":"loss_5_frequency","Type":"number","Label":"Loss 5 — estimated occurrences per week","HelpText":"","Required":false},{"Key":"loss_5_category","Type":"select","Label":"Loss 5 — primary category","HelpText":"","Required":false,"Options":[{"Value":"equipment","Label":"Equipment"},{"Value":"process","Label":"Process"},{"Value":"material","Label":"Material"},{"Value":"human","Label":"Human / training"},{"Value":"planning","Label":"Planning / scheduling"},{"Value":"tooling","Label":"Tooling / fixture"},{"Value":"environment","Label":"Environment / utilities"},{"Value":"data_systems","Label":"Data / systems"},{"Value":"other","Label":"Other"}]},{"Key":"loss_5_rank","Type":"select","Label":"Loss 5 — priority rank","HelpText":"","Required":false,"Options":[{"Value":"1","Label":"1 (highest)"},{"Value":"2","Label":"2"},{"Value":"3","Label":"3"},{"Value":"4","Label":"4"},{"Value":"5","Label":"5 (lowest)"}]},{"Key":"loss_5_root_brief","Type":"textarea","Label":"Loss 5 — observed immediate cause","HelpText":"","Required":false},{"Key":"loss_5_why_1","Type":"textarea","Label":"Loss 5 — Why #1","HelpText":"","Required":false},{"Key":"loss_5_why_2","Type":"textarea","Label":"Loss 5 — Why #2","HelpText":"","Required":false},{"Key":"loss_5_why_3","Type":"textarea","Label":"Loss 5 — Why #3","HelpText":"","Required":false},{"Key":"loss_5_why_4","Type":"textarea","Label":"Loss 5 — Why #4","HelpText":"","Required":false},{"Key":"loss_5_why_5","Type":"textarea","Label":"Loss 5 — Why #5","HelpText":"","Required":false},{"Key":"loss_5_experiment_hypothesis","Type":"textarea","Label":"Loss 5 — experiment hypothesis","HelpText":"","Required":false},{"Key":"loss_5_small_experiment_plan","Type":"textarea","Label":"Loss 5 — small experiment plan","HelpText":"","Required":false},{"Key":"loss_5_success_metrics","Type":"textarea","Label":"Loss 5 — success metrics","HelpText":"","Required":false},{"Key":"loss_5_owner","Type":"text","Label":"Loss 5 — owner for experiment","HelpText":"","Required":false},{"Key":"loss_5_target_date","Type":"text","Label":"Loss 5 — target completion date","HelpText":"","Required":false},{"Key":"loss_5_sustain_actions","Type":"textarea","Label":"Loss 5 — sustainment actions","HelpText":"","Required":false},{"Key":"sustainment_checklist","Type":"checkbox","Label":"Sustainment checklist — actions to confirm when experiment succeeds","HelpText":"Select actions you will perform if the experiment succeeds.","Required":false,"Options":[{"Value":"update_standard_work","Label":"Update standard work / procedures"},{"Value":"provide_training","Label":"Provide training / coaching"},{"Value":"install_poka_yoke","Label":"Install mistake-proofing"},{"Value":"secure_spares","Label":"Secure critical spare parts"},{"Value":"update_maintenance_plan","Label":"Update maintenance or PM tasks"},{"Value":"schedule_followup_audit","Label":"Schedule follow-up audit / verification"},{"Value":"document_changes","Label":"Document changes in system (WMS/MES)"}]},{"Key":"measurement_plan","Type":"textarea","Label":"Measurement plan for the diagnosis","HelpText":"Where and how you will collect data to validate the experiment result (who, what, when, sample size).","Required":false},{"Key":"expected_oee_gain_estimate","Type":"textarea","Label":"Estimated OEE gain if successful","HelpText":"Express as minutes saved, % availability/performance/quality, or other measurable benefit.","Required":false},{"Key":"next_steps","Type":"textarea","Label":"Next steps and team commitments","HelpText":"Who will do what next and by when.","Required":false},{"Key":"final_reflection","Type":"textarea","Label":"Team reflection after experiment","HelpText":"After the experiment, record outcomes, unexpected learnings, and further actions.","Required":false}]}