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Quest Training

Overall Equipment Effectiveness (OEE) Improvement Training Course

Shows how to measure availability, performance and quality through OEE, find production losses and cut unplanned downtime to raise output from current assets.

QE · Operational Excellence & Performance ImprovementAll Levels#2844ClassroomEnglish , Arabic
Duration
5 Days
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Free substitution at any time · 30+ days' notice: full refund minus 10%. Cancellation policy

Sectors:Quality Management & Operational ExcellenceCategories:Operational Excellence & Performance Improvement

Course Overview

Overall Equipment Effectiveness (OEE) is a key performance measurement tool used to evaluate how effectively manufacturing equipment operates against its full production potential. By measuring availability, performance, and quality, organizations can identify production losses, reduce unplanned downtime, improve equipment utilization, and increase manufacturing productivity without relying solely on additional capital investment. This course provides a practical framework for measuring, analysing, and improving OEE across manufacturing and industrial operations. Participants will explore the three OEE components, data collection methods, downtime classification, production loss analysis, and root cause investigation. The programme also examines the relationship between OEE, Total Productive Maintenance (TPM), Lean Manufacturing, preventive maintenance, and continuous improvement initiatives. Through practical exercises and realistic production scenarios, participants will learn to calculate OEE, establish performance baselines, identify the largest sources of equipment losses, and develop targeted improvement plans. The course emphasizes data accuracy, cross-functional collaboration, and sustainable performance monitoring to help organizations improve equipment reliability, reduce waste, and achieve measurable operational gains.

Learning Objectives

  • Explain the principles and business value of Overall Equipment Effectiveness.
  • Calculate OEE using availability, performance, and quality indicators.
  • Establish reliable OEE baselines and define realistic improvement targets.
  • Identify and classify equipment losses, downtime, speed losses, and quality defects.
  • Apply root cause analysis to recurring equipment and production problems.
  • Analyse OEE trends and production data to identify improvement opportunities.
  • Apply Lean Manufacturing and Total Productive Maintenance principles to reduce equipment losses.
  • Develop corrective actions that improve availability, operating speed, and first-pass quality.
  • Establish OEE dashboards, reporting routines, and performance accountability.
  • Develop an implementation plan to sustain OEE improvements and verify operational benefits.

Who Should Attend

Production and manufacturing managers. Plant managers and operations supervisors. Maintenance and reliability engineers. Industrial and manufacturing engineers. Continuous improvement and operational excellence specialists. Lean Manufacturing and Total Productive Maintenance practitioners. Quality assurance and process improvement professionals. Production planners and performance analysts. Engineering and technical teams responsible for equipment performance and productivity.

Learning Outcomes

  • Explain the three components of OEE and their contribution to equipment effectiveness.
  • Calculate availability, performance, quality, and overall OEE from production data.
  • Establish consistent data collection and downtime recording methods.
  • Identify the principal sources of equipment-related production losses.
  • Use OEE reports and trend analysis to investigate performance gaps.
  • Apply root cause analysis to recurring downtime and quality problems.
  • Select improvement measures appropriate to the identified equipment losses.
  • Integrate OEE improvement with maintenance, quality, and production management activities.
  • Develop dashboards and action plans with clear ownership and measurable targets.
  • Evaluate improvement results and establish mechanisms for sustaining performance gains.

Course Outline

Day 1

OEE Fundamentals, Measurement, and Performance Baselines

  • Introduction to OEE and its role in manufacturing performance management.
  • Understanding availability, performance, and quality as the three OEE components.
  • OEE calculation methods, formulas, interpretation, and reporting conventions.
  • Defining planned production time, operating time, ideal cycle time, and total output.
  • Distinguishing planned stops, unplanned downtime, minor stops, and production interruptions.
  • Establishing data collection standards and validating production records.
  • Selecting equipment, production lines, and measurement periods for OEE assessment.
  • Understanding the difference between equipment-level OEE and broader production performance indicators.
  • Practical Exercise: Calculate OEE for a representative production line using sample operating data, establish a baseline, and identify the main contributors to performance loss.
Day 2

Production Loss Analysis and Root Cause Investigation

  • Understanding the major equipment losses associated with availability, performance, and quality.
  • Classifying downtime and developing a consistent downtime coding structure.
  • Analysing equipment breakdowns, setup and adjustment time, and minor stoppages.
  • Investigating reduced operating speed, cycle-time variation, and idle running.
  • Evaluating startup rejects, process defects, rework, and scrap.
  • Applying Pareto analysis to rank the largest sources of production loss.
  • Using the Five Whys, fishbone diagrams, and structured problem-solving techniques.
  • Distinguishing symptoms from root causes and validating findings with operational data.
  • Practical Exercise: Analyse a sample downtime and defect dataset, identify the most significant OEE losses, and develop a root cause analysis for the highest-priority problem.
Day 3

Improving Availability Through Maintenance and Reliability

  • Relationship between OEE, equipment reliability, maintainability, and production availability.
  • Analysing breakdown frequency, repair duration, and recurring equipment failures.
  • Applying preventive and predictive maintenance to reduce unplanned downtime.
  • Introduction to Total Productive Maintenance (TPM) and autonomous maintenance.
  • Improving equipment inspection, lubrication, cleaning, and early fault detection.
  • Reducing setup and changeover time using structured changeover improvement methods.
  • Improving spare parts readiness, maintenance planning, and coordination with production teams.
  • Establishing maintenance-related indicators and verifying their impact on OEE.
  • Practical Exercise: Review an equipment downtime history, identify reliability improvement opportunities, and prepare a targeted action plan to increase availability.
Day 4

Improving Performance and Quality Components of OEE

  • Identifying speed losses, reduced cycle rates, and minor equipment stoppages.
  • Comparing actual cycle times with ideal cycle times and rated equipment capacity.
  • Standardizing operating parameters and reducing unnecessary process variation.
  • Applying Lean principles to improve workflow, material supply, and production flow.
  • Analysing startup losses, defects, scrap, and rework.
  • Using process control, standard work, and operator feedback to improve first-pass quality.
  • Coordinating production, maintenance, and quality teams to address recurring losses.
  • Evaluating improvement effectiveness through controlled comparisons and performance trends.
  • Practical Exercise: Analyse a production scenario with speed losses and quality defects, calculate the impact on OEE, and recommend targeted improvements for performance and quality.
Day 5

OEE Improvement Roadmap, Performance Governance, and Sustainability

  • Establishing OEE targets aligned with production requirements and business objectives.
  • Prioritizing improvement projects according to loss contribution, feasibility, cost, and expected benefit.
  • Developing action plans with milestones, accountable owners, resources, and completion dates.
  • Designing OEE dashboards and daily, weekly, and monthly performance review routines.
  • Integrating OEE with maintenance management, production planning, and quality systems.
  • Establishing escalation procedures and accountability for recurring performance losses.
  • Verifying improvements through consistent data collection and before-and-after comparisons.
  • Standardizing successful practices and embedding continuous improvement into daily operations.
  • Practical Exercise: Develop a 90-day OEE improvement roadmap for a selected production line, including baseline performance, prioritized loss-reduction initiatives, measurable targets, responsibilities, and review mechanisms.

Upcoming Dates

Selected date

Istanbul · 20 – 24 Sept 2027 · Classroom

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