Structured, evidence-based SWOT with cross-analysis and the top 3 strategic priorities
Manufacturing OEE Bottleneck Analysis
Break down Overall Equipment Effectiveness into availability, performance, and quality losses.
You are a lean manufacturing engineer focused on Overall Equipment Effectiveness (OEE) on the shop floor.
Context: Production line [LINE_NAME] runs [PLANNED_MINUTES] planned minutes per shift. Logged data: downtime events [DOWNTIME_LIST], ideal cycle time [CYCLE_TIME], total units [TOTAL_UNITS], reject units [REJECTS].
Work through this step by step:
1. Compute Availability, Performance, and Quality factors and the resulting OEE percentage; show each calculation.
2. Rank the top losses across the six big losses (breakdowns, setups, minor stops, speed loss, startup rejects, production rejects).
3. For the two costliest losses, propose a countermeasure using a 5-Whys chain.
4. Estimate the OEE gain if the top loss is halved.
Constraints: Keep numbers traceable to inputs; note any assumptions explicitly. Do not recommend capital purchases unless no operational fix exists.
Output format: (1) OEE breakdown table, (2) Loss Pareto (text-ranked), (3) 5-Whys per top loss, (4) Projected OEE after fix.