OEE Rapid Diagnosis Workbook

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

OEE Rapid Diagnosis Workbook

Use this workbook during or immediately after a shift to validate OEE inputs, capture the largest losses, run a short 5‑whys, and define a single prioritized experiment for the next shift. Fill what you can — required fields are marked. If your MES or historian can pre-fill counts and times, use those values to improve accuracy.

Short coaching script for the shift review

Supervisor: \"Two-minute huddle — this was our top loss, here's what we contained, likely root cause, and the experiment we'll run next shift. Who owns it and what will you measure?\" Capture commitments in 'Follow-up actions'.

", "SubmitLabel": "Save Workbook", "SuccessMessage": "Workbook saved. Share with your CI lead and run the planned experiment next shift. Repeat the workbook after the experiment to measure impact.", "DataType": "OEERapidDiagnosisSubmission", "SchemaVersion": "1.0", "Fields": [ {"Key": "shift_date","Label": "Shift date (YYYY-MM-DD)","FieldType": "text","HelpText": "Enter the shift date. Use ISO format to help aggregation.","Required": true}, {"Key": "shift_label","Label": "Shift","FieldType": "select","Options": [{"Label": "Day","Value": "day"},{"Label": "Swing","Value": "swing"},{"Label": "Night","Value": "night"},{"Label": "Other","Value": "other"}],"HelpText": "Select the shift.","Required": true}, {"Key": "line_name","Label": "Line / Cell / Machine","FieldType": "text","HelpText": "Where this workbook applies.","Required": true}, {"Key": "operator_name","Label": "Operator(s)","FieldType": "text","HelpText": "Name(s) of operator(s) on shift."}, {"Key": "supervisor_name","Label": "Supervisor","FieldType": "text"}, {"Key": "planned_production_minutes","Label": "Planned production time (minutes)","FieldType": "number","HelpText": "Total planned production minutes for the shift (scheduled time minus planned breaks).","Required": true}, {"Key": "planned_breaks_minutes","Label": "Planned breaks / lunch (minutes)","FieldType": "number","HelpText": "Planned non-production time included in the schedule."}, {"Key": "unplanned_stopped_minutes","Label": "Unplanned stopped time (minutes)","FieldType": "number","HelpText": "Total unplanned stoppages observed during the shift. Use loss capture details below for specifics.","Required": true}, {"Key": "operating_time_minutes","Label": "Operating time (minutes)","FieldType": "number","HelpText": "Planned production time minus planned breaks minus unplanned stopped time. Validate this number.","Required": true}, {"Key": "ideal_cycle_time_sec","Label": "Ideal cycle time (seconds)","FieldType": "number","HelpText": "Standard cycle time per good part (seconds).","Required": true}, {"Key": "total_count","Label": "Total produced (count)","FieldType": "number","HelpText": "Total pieces produced (good + scrap) during operating time.","Required": true}, {"Key": "good_count","Label": "Good parts (count)","FieldType": "number","HelpText": "Number of acceptable parts. If unavailable, estimate and mark confidence below.","Required": true}, {"Key": "availability_pct","Label": "Availability (%) — optional","FieldType": "number","HelpText": "Optional: Availability = Operating time / Planned production time × 100. You may fill if calculated elsewhere."}, {"Key": "performance_pct","Label": "Performance (%) — optional","FieldType": "number","HelpText": "Optional: Performance = (Ideal cycle time × Total count) / Operating time (convert units) × 100."}, {"Key": "quality_pct","Label": "Quality (%) — optional","FieldType": "number","HelpText": "Optional: Quality = Good count / Total count × 100."}, {"Key": "oee_pct","Label": "OEE (%) — optional","FieldType": "number","HelpText": "Optional: OEE = Availability × Performance × Quality (expressed as percent)."}, {"Key": "data_confidence","Label": "Confidence in inputs","FieldType": "scale","HelpText": "How confident are you in the numbers above? 1 = low, 5 = high.","Required": true,"Min": 1,"Max": 5}, {"Key": "loss_top_count","Label": "How many loss events will you record here? (1–3)","FieldType": "select","Options": [{"Label": "1","Value": "1"},{"Label": "2","Value": "2"},{"Label": "3","Value": "3"}],"HelpText": "Choose how many individual loss lines you will fill below. Use the most significant losses first.","Required": true}, {"Key": "loss_1_category","Label": "Loss #1 — Category","FieldType": "select","Options": [{"Label": "Availability (stops)","Value": "availability"},{"Label": "Performance (speed losses)","Value": "performance"},{"Label": "Quality (scrap/rework)","Value": "quality"}],"Required": true}, {"Key": "loss_1_start_minute","Label": "Loss #1 — Approx start minute of shift","FieldType": "number","HelpText": "Approximate minute within the shift when the loss began (0 = shift start)."}, {"Key": "loss_1_duration_minutes","Label": "Loss #1 — Duration (minutes)","FieldType": "number","HelpText": "Duration of this loss event in minutes.","Required": true}, {"Key": "loss_1_short_description","Label": "Loss #1 — Short description","FieldType": "textarea","HelpText": "Describe what happened (one or two sentences).","Required": true}, {"Key": "loss_1_containment","Label": "Loss #1 — Immediate containment action taken","FieldType": "textarea","HelpText": "What was done to continue production or limit damage?"}, {"Key": "loss_1_5whys","Label": "Loss #1 — Quick 5‑Whys (root cause notes)","FieldType": "textarea","HelpText": "List up to five 'why' steps or a short root-cause summary."}, {"Key": "loss_1_estimated_impact_minutes","Label": "Loss #1 — Estimated lost minutes (impact)","FieldType": "number","HelpText": "Estimated minutes lost attributable to this event."}, {"Key": "loss_1_estimated_scrap","Label": "Loss #1 — Estimated scrap / rework (count)","FieldType": "number","HelpText": "If quality loss, estimate scrap count attributable to this event."}, {"Key": "loss_1_owner","Label": "Loss #1 — Owner for next-step experiment","FieldType": "text"}, {"Key": "loss_1_priority","Label": "Loss #1 — Triage priority","FieldType": "select","Options": [{"Label": "Do now (High impact, easy)","Value": "high"},{"Label": "Plan (High impact, medium/hard)","Value": "medium"},{"Label": "Defer (Low impact)","Value": "low"}],"HelpText": "Use quick triage to choose focus."}, {"Key": "loss_1_confidence","Label": "Loss #1 — Confidence in root cause (1–5)","FieldType": "scale","Min": 1,"Max": 5}, {"Key": "loss_2_category","Label": "Loss #2 — Category","FieldType": "select","Options": [{"Label": "Availability (stops)","Value": "availability"},{"Label": "Performance (speed losses)","Value": "performance"},{"Label": "Quality (scrap/rework)","Value": "quality"}]}, {"Key": "loss_2_duration_minutes","Label": "Loss #2 — Duration (minutes)","FieldType": "number"}, {"Key": "loss_2_short_description","Label": "Loss #2 — Short description","FieldType": "textarea"}, {"Key": "loss_2_5whys","Label": "Loss #2 — Quick 5‑Whys","FieldType": "textarea"}, {"Key": "loss_2_owner","Label": "Loss #2 — Owner","FieldType": "text"}, {"Key": "loss_2_priority","Label": "Loss #2 — Triage priority","FieldType": "select","Options": [{"Label": "Do now","Value": "high"},{"Label": "Plan","Value": "medium"},{"Label": "Defer","Value": "low"}]}, {"Key": "loss_2_confidence","Label": "Loss #2 — Confidence (1–5)","FieldType": "scale","Min": 1,"Max": 5}, {"Key": "loss_3_category","Label": "Loss #3 — Category","FieldType": "select","Options": [{"Label": "Availability (stops)","Value": "availability"},{"Label": "Performance (speed losses)","Value": "performance"},{"Label": "Quality (scrap/rework)","Value": "quality"}]}, {"Key": "loss_3_duration_minutes","Label": "Loss #3 — Duration (minutes)","FieldType": "number"}, {"Key": "loss_3_short_description","Label": "Loss #3 — Short description","FieldType": "textarea"}, {"Key": "loss_3_5whys","Label": "Loss #3 — Quick 5‑Whys","FieldType": "textarea"}, {"Key": "loss_3_owner","Label": "Loss #3 — Owner","FieldType": "text"}, {"Key": "loss_3_priority","Label": "Loss #3 — Triage priority","FieldType": "select","Options": [{"Label": "Do now","Value": "high"},{"Label": "Plan","Value": "medium"},{"Label": "Defer","Value": "low"}]}, {"Key": "loss_3_confidence","Label": "Loss #3 — Confidence (1–5)","FieldType": "scale","Min": 1,"Max": 5}, {"Key": "selected_top_losses","Label": "Select the top loss(es) to address next shift","FieldType": "checkbox","Options": [{"Label": "Loss #1","Value": "loss_1"},{"Label": "Loss #2","Value": "loss_2"},{"Label": "Loss #3","Value": "loss_3"}],"HelpText": "Check the loss(es) you plan to act on. Prefer 1–2 items."}, {"Key": "experiment_owner","Label": "Experiment owner","FieldType": "text","HelpText": "Person responsible for running and reporting the experiment.","Required": true}, {"Key": "experiment_description","Label": "Experiment description (what will you try?)","FieldType": "textarea","HelpText": "Describe the quick change, containment improvement, or test you will run next shift. Keep it small and observable.","Required": true}, {"Key": "experiment_success_metric","Label": "Success metric (how will you measure success?)","FieldType": "text","HelpText": "Example: reduce repeat stops from X to Y, save Z minutes, reduce scrap by N parts.","Required": true}, {"Key": "measurement_method","Label": "Measurement method (how will you collect results?)","FieldType": "text","HelpText": "Example: shift log, MES counter, sample check every hour."}, {"Key": "test_duration_shifts","Label": "Test duration (number of shifts)","FieldType": "number","HelpText": "How many shifts will you run the experiment before review?"}, {"Key": "review_notes","Label": "Shift review notes","FieldType": "textarea","HelpText": "Short notes from the shift huddle. Who committed to what?"}, {"Key": "follow_up_actions","Label": "Follow-up actions (who will do what, by when)","FieldType": "textarea","HelpText": "Capture commitments and dates. Useful for handover to CI or next shift."}, {"Key": "submit_for_review","Label": "Submit workbook for CI review?","FieldType": "yesno","HelpText": "Choose Yes to notify CI or save for local review."} ] }