The floor isn't performing
“Our OEE looks fine, but we keep missing output.”
OEE is on the board and it looks healthy. Yet orders ship late, overtime keeps climbing, and the plant never seems to have enough capacity. Somewhere between how OEE is calculated and what really happens on the floor, the truth got lost.
Request a Situation ReviewWhat you're facing
- •Planned downtime, changeovers, or small stops excluded from the calculation.
- •Ideal cycle times set so loosely that performance always looks good.
- •OEE entered by hand at the end of the shift from memory.
- •Different lines calculating OEE different ways.
What it's costing you
- •Capacity you think you have but do not — so you promise dates you cannot hit.
- •Overtime and expediting to cover the gap.
- •Capital spent on new equipment when the old equipment had hidden capacity.
- •Improvement effort aimed at the wrong losses.
The questions you're probably asking
- •Are we calculating OEE correctly?
- •Why doesn't our OEE match our output?
- •Should we automate OEE data collection?
- •Which losses should we attack first?
Answer these before you spend another dollar
- 1What is excluded from our OEE calculation — and who decided that?
- 2Where do our ideal cycle times come from?
- 3Is OEE captured automatically or written down after the fact?
- 4Do all lines use the same definitions?
- 5Does good output per scheduled hour match what OEE implies?
How we solve it
The Exceleor Path, tailored to your situation
We make OEE honest: consistent definitions, real ideal rates, and automated capture where it pays — so the losses you see are the losses you have, and improvement goes where it counts.
Discovery
Understand the problem, measure where things stand today, and agree on what success looks like.
In your situation: An OEE audit: definitions, exclusions, ideal rates, and data capture compared with actual output.
Define the engagement path
Most organizations don't know the path. We do. A proven method, tailored to your situation.
In your situation: Standard OEE definitions and a loss model for your lines, with automated capture where it pays.
Training
Bring your people to a clear understanding of what is changing and why.
In your situation: Supervisors and operators trained to capture and read losses the same way.
Implement and engage
Carry out the work jointly, with your people involved from day one.
In your situation: Data capture and loss reporting deployed on your priority lines.
Verify
Confirm the work was done and meets the requirement.
Validate
Confirm the original problem is actually solved, measured against the success measures from Discovery.
Transfer ownership
We collaborate throughout, so your team can run it without us.
In your situation: Your team owns the definitions, the data, and the loss review routine.
Sustain and grow
We stay close, check in, and catch the next need early. We're here to make sure you succeed.
What you'll have at the end
- An OEE number that matches what ships.
- Consistent definitions across lines and shifts.
- A clear, ranked picture of where capacity is lost.
- Improvement and capital decisions based on real losses.
Related services & tools
Situation Review
Tell us what's going on
Share the details — your plant, your timeline, what has already happened. We will reply by email with an honest assessment of where you stand and the path forward. No obligation.