Understand your true production potential
Even small improvements in OEE can unlock significant production gains. But what value will it actually bring you?
Follow the steps and use the calculator below to estimate the financial impact of improving your OEE to understand how much additional output and revenue you could generate.
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Calculate your OEE
Enter your production data, see your Overall Equipment Effectiveness, and get a better understanding of your productivity.
Enter your data
Total equipment time
e.g 2 shifts x 8 hours x 60 minutes = 480 minutes per day
minutes
Total non-operational time
e.g. Time lost due to planned downtime
(maintenance, meetings, breaks, cleaning)
minutes
Total performance loss time
e.g. Time lost due to breakdowns, jams, errors, reduced speed, and micro-stops
minutes
Target / expected speed
e.g. Ideal production speed, such as 500 units per minute
units per minute
Scrap units
e.g. Total scrap units
units
OEE results
Availbility
0 %
Performance
0 %
Quality
0 %
Your current OEE:
0 %
See how you compare to other manufacturing leaders
Now that you have your baseline OEE, compare it to other manufacturers in your industry, and learn what they’re doing to improve.
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 9 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 7 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 10 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 18 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 2 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 9 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 11 points*
Your baseline OEE
Baseline OEE Industry Average
After 90 days of using Factbird
+ 5 points*
How does your baseline OEE compare to your competition?
Your current OEE is below when compared to other manufacturers that use Factbird in your specific industry.
What does it mean if you are below the industry baseline?
Your production process likely has strong potential for rapid improvement.
Our benchmark data shows that lines with a lower baseline OEE often achieve faster and more significant early gains.
Your current OEE is similar to other manufacturers that use Factbird in your specific industry.
What does it mean if you are around the average industry baseline?
Your productivity performance is on par with many manufacturers that are using Factbird. This means that your OEE represents a typical starting point, but you still have proven potential for comparable improvements.
Your current OEE is above average when compared to other manufacturers that use Factbird in your specific industry.
What does it mean if you are above the industry baseline?
Your production processes are likely already highly optimized. As lines with a higher baseline OEE typically see smaller, incremental improvements, the focus shifts from large gains to small changes, and to maintain consistency and stability.
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Improve your OEE
Most manufacturing operations have significant hidden capacity. Improving availability, performance, or quality by just a few percentage points can translate into major productivity gains.
With Factbird, manufacturers gain real-time insights into production performance, making it easier to identitify losses and consinously improve OEE.
Want to see what that's worth in your factory?
The financial impact of improving your OEE
Calculate and get an estimation of how increasing your OEE impacts your production output and revenue.
Enter your data
Current OEE
%
Target OEE
Your desired OEE
%
Produced units per hour
units per hour
Annual labor costs
USD
ROI results
Produced units per hour
with target OEE
{0}
units per hour
Annual labor cost
with target OEE
{0}
USD
Unit produced increase
{0}
units more per hour
Unit produced percentage increase
{0}
%
Yearly direct labor cost saving
{0} USD
Fill out the form and get your ROI calculation and recommendations on how you can improve your OEE.
Unlock the ROI calculatorYour Estimated OEE Improvement Impact
Based on the information you provided, improving your OEE could significantly increase your production capacity and revenue.
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Unlocking hidden production capacity
Many manufacturers are under pressure to produce more with tighter margins, higher complexity, and fewer experienced operators.
This is why leadership teams are pushing digitalization into daily operations. They want to better understand where time is lost, respond faster to recurring issues, and ensure that improvements are sustained across shifts and sites.
Improving your OEE helps unlock this hidden capacity without needing to invest in new machines or scheduling extra shifts.
Based on your inputs, increasing your OEE from {current_oee} % to {target_oee} % would enable you to produce approximately {additional_units} more units per hour. That uquals a {unit_produced_increase} % increase in productivity and could potential save you {yearly-direct-cost-saving} USD in annual labor cost.
Even small improvements in availability, performance, or quality can drive significant gains in both productivity and profitability.
Learning from leading manufacturers delivering proven result
Select a different industryCommon challenges across all industries
Manufacturers are under pressure to produce more reliably with tighter margins, higher complexity, and fewer experienced hands. Supply chain volatility, rising input costs, and rapidly shifting demand are compressing the time you have available to react.
Shorter runs, more SKUs, and an ageing workforce mean variability is rising on the floor, while predictability drops in your planning. The pressure to show measurable improvement has never been higher.
Opportunities to improve OEE
- Recurring unplanned downtime and nuisance stops
- Micro-stops and speed losses that add up across a shift
- Changeovers and start-up stability
- Quality deviations tied to repeatable causes
Common challenges in Food & Beverage
Food and Beverage manufacturers run under constant throughput pressure, with tight quality requirements and hygiene routines that shape how lines stop and restart.
Even in highly automated environments, the day still contains a surprising amount of friction. Short resets, minor interruptions, and changeover variation can add significant capacity loss. That's why unplanned disruption is a recurring theme in the sector.
Opportunities to improve OEE
- Recurring unplanned downtime patterns on critical assets
- Micro-stops and short interruptions that add up across a shift
- Changeover and cleaning-related variation, including start-up stability
- Recurring quality-related holds or rework triggers
Common challenges in CPG
CPG manufacturing sits in a constant balancing act between volume and variety. Many sites run high output targets while changing products, formats, and packaging configurations frequently. That reality creates friction in the day.
Changeovers, short resets, and small interruptions become part of the rhythm, and they can be hard to challenge because they are so familiar.
Opportunities to improve OEE
- Changeover losses and start-up stability, especially where variation between teams is high
- Short interruptions tied to packaging flow, jams, and resets that repeat across shifts
- Operator-driven variation in stop classification and recovery routines
- Wear-related recurring stops that become predictable once tracking is consistent
Common challenges in Packaging & containers
Packaging and containers manufacturers operate in a high change environment. Material availability, cost pressure, and sustainability requirements can all force frequent adjustments to formats, suppliers, and specifications. That increases day-to-day variability, especially on lines where minor settings and small deviations can trigger production stops.
Stops, resets, jams, short quality holds, and changeover variation can feel normal until they are measured consistently.
Opportunities to improve OEE
- Changeover and start-up stability, especially where formats and materials vary frequently
- Short interruptions related to flow, handling, jams, and resets that repeat across shifts
- Speed losses caused by small recurring constraints that are hard to see without consistent tracking
- Recurring downtime once loss categories are stable and trusted
Common challenges in Industrial equipment & devices
Industrial equipment and device manufacturing usually blends machining, assembly, and test, with meaningful variation run-to-run. Products change. Routings change. Engineering changes happen midstream. That makes performance losses harder to compare across stations and shifts.
When teams lack shared definitions for stops, speed losses, and waiting time, the discussion drifts into anecdotes, and improvement work gets stuck in debates instead of turning into repeatable habits.
Opportunities to improve OEE
- Repeat downtime on shared constraints, tools, or stations
- Speed losses tied to tooling condition, setup settings, and warm-up or first-piece stability
- Waiting time and handovers between machining, assembly, and test that create hidden stops
- Repeat quality holds or rework triggers that show up across similar parts or routings
Common challenges in Pharma & medical devices
Pharma and medical devices manufacturing runs under strict regulatory and validation requirements. Changes to processes, equipment, and systems often require approval, documentation, and revalidation. That reality shapes what "fast progress" can look like, because implementation speed is constrained by quality and compliance guardrails.
Opportunities to improve OEE
- Recurring micro-stops or short interruptions on critical equipment
- Changeovers and start-up stability, especially where documentation is required
Common challenges in Construction & Building
Construction and Building manufacturers often operate in an environment shaped by volatile input costs, tight delivery expectations, and regulatory pressure on the footprint of materials.
For many producers tied to concrete, cement, and other building materials, decarbonization requirements are also rising alongside everyday demands for output and reliability.
Opportunities to improve OEE
- Making variability visible and manageable across sites
- Separating normal variation from repeatable losses that are actually worth acting on
Common challenges in Automotive parts & components
Automotive parts and components manufacturers run lean, with delivery schedules often tied to OEM assembly lines and little room for disruption. Most sites carry a wide part number mix, which brings frequent changeovers and a production pattern where small, repeated losses are easy to normalize.
Across multi-site operations, inconsistent ways of recording those losses make it hard to tell whether a gap between plants is a real performance difference or just a measurement one.
Opportunities to improve OEE
- Tightening execution around a small set of recurring losses
- Integrating production data into existing Lean routines
- Investigate stability and performance during new platform and model transitions
How to gain measurable gains
Factbird's Manufacturing Intelligence suite is built for the shop floor. It brings together apps, data-capture devices, and insights in one system, so you can manage performance, data and workflows without juggling scattered tools.
Production Insights
Get real-time, detailed visibility into performance so you can boost productivity. Spot losses early, understand why they happen, and focus your efforts on the improvements that make the biggest impact.
Connected Operations
Digitize workflows, from SOPs to maintenance checks, so front-line teams stay aligned, and collaboration becomes easier.
Knowledge Excellence
Develop your workforce and processes in a structured way and keep operations running smoothly with the right skills in the right place.
What a 9 7 10 18 2 9 11 5 point OEE Improvement Could Mean
Based on Factbird benchmark report, all industries manufacturers on average achieve a 9 7 10 18 2 9 11 5 point OEE increase and 19 15 29 45 6 23 28 10% productivity improvement within just three months with Factbird.
Improving OEE in your shopfloor can result in:
- Significant increases in production output
- Better utilization of existing equipment
- Reduced production bottlenecks
- Higher revenue without additional capital investment
Keep exploring
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A practical guide to: Downtime, stop causes, and micro-stops
This is a practical guide that helps you define and separate downtime from micro-stops, build a shared reason list your team will actually use, and run a review rhythm that turns repeat patterns into fixes. Including a 30-day rollout plan.
Frequently Asked Questions
Was ist OEE-Software?
OEE-Software (Overall Equipment Effectiveness, Gesamtanlageneffektivität) berechnet und verfolgt die Anlagenleistung automatisch in Echtzeit. Sie misst drei Schlüsselfaktoren:
- Verfügbarkeit (Betriebszeit vs. Stillstandszeit)
- Leistung (tatsächliche Geschwindigkeit vs. Sollgeschwindigkeit)
- Qualität (einwandfreie Teile vs. insgesamt produzierte Teile)
Statt manueller Berechnungen oder Tabellen zieht OEE-Software die Daten direkt von Ihren Produktionslinien und zeigt sofort, wo Effizienz verloren geht.
Wie berechnet man Gesamtanlageneffektivität (OEE)?
Gesamtanlageneffektivität (OEE) wird als Produkt aus drei Faktoren berechnet:
- Verfügbarkeit × Leistung × Qualität = OEE
Verfügbarkeit vergleicht tatsächliche Produktionszeit mit geplanter Zeit. Leistung vergleicht die reale Ausbringungsgeschwindigkeit mit der Sollgeschwindigkeit. Qualität setzt einwandfreie Teile ins Verhältnis zur Gesamtstückzahl. Das Ergebnis wird in Prozent angegeben.
Beispiel: Läuft Ihre Linie 90 % der geplanten Zeit, erreicht 95 % der Sollgeschwindigkeit und produziert 98 % einwandfreie Teile, ergibt sich eine OEE von 84 % (0,90 × 0,95 × 0,98 ≈ 0,837). Für einen Einblick in OEE und die Berechnung empfehlen wir unseren Blog: Kurzanleitung zur Gesamtanlageneffektivität (OEE).
Wie berechnet Factbird die Gesamtanlageneffektivität (OEE)?
Factbird nutzt Sensordaten über Plug-and-Play-IIoT-Edge-Geräte, Integrationen mit Software wie Kepware sowie direkte SPS-Integrationen, um Stückzahlen, Stillstandsereignisse und Qualitätskennzahlen automatisch zu erfassen. Auf Basis der Realdaten und Eingaben in das intuitive Kategorisierungssystem Operator View wird die Gesamtanlageneffektivität (OEE) kontinuierlich berechnet.
Mit Factbird erhalten Sie OEE-Werte in Echtzeit – für einzelne Maschinen, Chargen, Schichten, Linien oder Ihr gesamtes Werk.
Können wir die OEE-Berechnung an unseren Prozess anpassen?
Ja. In Factbird können Sie eigene Stoppkategorien, ideale Taktzeiten und Qualitätsparameter definieren – exakt passend zu Ihrem Fertigungsprozess. Sie können Gesamtanlageneffektivität (OEE) je Produkttyp, Schicht oder Linie differenziert verfolgen und behalten dabei konsistente Reporting-Standards.
Wie schnell sehen wir OEE-Verbesserungen?
Die meisten Hersteller sehen innerhalb weniger Stunden nach der Installation umsetzbare Erkenntnisse. Spürbare Verbesserungen beginnen typischerweise innerhalb von Wochen, wenn wiederkehrende Probleme identifiziert und eliminiert werden. Basierend auf Kundendaten von 2016 bis 2022 steigerten Hersteller mit Factbird ihre Gesamtanlageneffektivität (OEE) im ersten Jahr im Durchschnitt um 10–25 %.
Worin liegt der Unterschied zwischen OEE-Software und Produktionsüberwachungssoftware?
OEE-Software berechnet gezielt die Gesamtanlageneffektivität nach den Standardfaktoren Verfügbarkeit, Leistung und Qualität. Produktionsüberwachungssoftware ist breiter aufgestellt und verfolgt zusätzliche Kennzahlen wie Durchsatz, Taktzeiten und Stillstandsursachen. Factbird vereint beides in einem System: präzise OEE-Berechnung und umfassende Produktionsüberwachung – für datengestützte Entscheidungen in Echtzeit.