Overall Equipment Effectiveness (OEE)

Butler Automatic Boosts OEE

Overall Equipment Effectiveness (OEE) is one of the most important topics in packaging today. Improving your OEE will help you significantly increase your packaging line’s output. Butler Automatic‘s film splicers eliminate roll change downtime giving packaging lines the largest potential OEE boost available.

Overall Equipment Effectiveness Calculation

Overall Equipment Effectiveness (OEE) is the benchmark used to measure the efficiency of a packaging line. The widely recognized formula for OEE is: Availability (A) multiplied by Performance (P) multiplied by Quality (Q).

Availability represents the up-time of your line after all planned and unplanned production stops (including breaks, lunch, maintenance, planned stops, and unplanned stops) have been accounted for. Typical availability for an 8 hour shift might be 77% when SKU changes, breaks, and roll change downtime are accounted for (110 minutes). To calculate availability, take the total hours of a shift (8 hours equals 480 minutes) and subtract the total downtime (110 minutes). The result is 370 minutes of total up-time of your line. Then take the total up-time (370 minutes) and divide it by the total shift time (480 minutes). Take the result (.77) and multiply it by 100 to reach the availability score of 77%

Performance measures the actual output of the line compared to the ideal rate. If your line is specified to run at 120 pouches per minute (ppm) and you are achieving 96 ppm, your performance factor is 96 divided by 120, or 80%.

The Quality measurement accounts for defects produced, good products output count or total product output count. If your total output is 96 ppm, and your machine ran for an 8 hour shift (480 minutes) with 110 minutes of downtime (lunch, 2 breaks, and roll change downtime) 35,520 total line output pouches would be produced (480 – 110 = 370; 370 x 96 = 35,520) . If 500 pouches are rejected, the quality measurement is calculated by taking the total line production (35,520), subtract the rejected pouches (500). Then divide the result (35,020) by total line output (35,520) and the result is .9859 or 98.6%

In this case the Overall Equipment Effectiveness score would be .77 x .80 x .986 = 60.7%

Automatic splicing eliminates the downtime resulting from roll changes (50 minutes in the above example), allows faster operation, and reduces waste. If we recalculate the OEE assuming the elimination of roll change downtime and the improved quality due to fewer pouches rejected around the splice (250 instead of 500 rejected pouches), our result is:

Availability:         420 / 480 = 87.5%

Performance:     remains the same

Quality:               35,270 / 35,520 = 99.3%

 The final OEE calculation is .875 x .80 x .993 = 69.5% which is 9 points of OEE improvement, or a 15% improvement!


Butler Automatic is the leader in providing splicing solutions to the packaging industry. With more than two thousand SP1 splicers installed on VFFS, HFFS, thermo forming, flow wrapping, shrink bundling and sleeving packaging applications, Butler Automatic is a trusted resource when it comes to increasing overall factory output by eliminating roll change downtime. 

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