OEE (Overall Equipment Effectiveness)

OEE (Overall Equipment Effectiveness) is the industry-standard measure of manufacturing efficiency. It combines three factors: - **Availability** (% time the line was actually running vs scheduled): typical 88-94% - **Performance** (% of nameplate speed actually achieved): typical 85-92% - **Quality** (% of bottles passing inspection): typical 96-99% OEE = Availability × Performance × Quality A well-run 60 BPM water plant typically achieves 78-84% OEE. World-class is > 85%; below 70% indicates significant losses worth investigating. Loss buckets to monitor: - **Planned downtime:** changeovers, scheduled CIP, maintenance - **Unplanned downtime:** breakdowns, no-feed, no-cap, no-bottle, no-air - **Speed losses:** running below nameplate due to label feeder, capper, or filler limits - **Quality losses:** rejects from short-fill, cap-misalignment, label issues Modern plants instrument the line with PLC-fed dashboards that track OEE in real-time, enabling specific loss-reduction projects.