Manufacturing COO
Your Dashboard Shows 82% OEE
Reality Is 61%
Micro-stops under 5 minutes don't get logged. Startup speed losses aren't counted. Rework isn't tagged as quality loss. That 21-point gap is $4.2M in phantom production.
The OEE Gap Your MES Hides
Reported vs. True OEE - side by side
What Your Dashboard Shows
World-Class Performance!
Based on MES standard calculations
What Reality Shows
Below Industry Average (65%)
Including all losses
21-point gap = $4.2M annually in production capacity you think you have but don't.
Where the 21 Points Disappear
Breaking down Availability × Performance × Quality
| Factor | Reported | Actual | Gap | Hidden Loss |
|---|---|---|---|---|
| Availability | 92% | 84% | -8% | Micro-stops <5min not logged |
| Performance | 95% | 82% | -13% | Speed losses during startup |
| Quality | 94% | 89% | -5% | Rework not counted as loss |
| OEE Total | 82% | 61% | -21% | $4.2M Lost |
OEE = Availability × Performance × Quality. Reported: 92% × 95% × 94% = 82%. Actual: 84% × 82% × 89% = 61%.
The $4.2M in Hidden Losses
What your MES doesn't capture - but your P&L feels
Micro-stops (<5 min)$1.24M
847 hrs
Startup/Ramp Speed Loss$910K
623 hrs
Unplanned Changeovers$600K
412 hrs
Quality Rework (hidden)$520K
356 hrs
Minor Adjustments$435K
298 hrs
Operator Wait Time$390K
267 hrs
Manufacturing KPIs That Tell the Truth
SlideStrike calculates these from machine-level data
True OEE
61%
Benchmark: 85%
MTBF
4.2 hrs
Benchmark: >8 hrs
First Pass Yield
89%
Benchmark: >98%
Changeover Time
47 min
Benchmark: <15 min
Defect Rate (PPM)
4,200
Benchmark: <500
Throughput Rate
82%
Benchmark: >95%
Source: Industry Week Best Plants Benchmarks 2025, AME OEE World-Class Standards
TRANSFORM YOUR OPERATIONS
See Your True OEE - Every Machine, Every Shift
SlideStrike connects to your machine PLCs and captures every micro-stop, speed loss, and quality issue your MES misses.
Real-time OEE from PLC/SCADA with micro-stop capture
Automated speed loss detection during ramp-up
Quality loss attribution including rework cycles
Board-ready production efficiency presentations