Industries
High-mix shops, make-to-order work, and a machine that spends the day changing over.
A high-mix plant does not run one product long enough for a textbook OEE score to mean what it means on a dedicated line. Twenty changeovers in a shift is the work. The kit for the next job is often what stops the spindle.
Lot sizes dropped so the shop could take the order. Setup is now planned work, not an interruption. When the report still books it as downtime, the board and the floor stop agreeing — even on days the schedule went out complete.
The spindle waits on a kit, a tool, or a program that is not at the machine. The job is released. The first piece is not.
World-class 85 percent is a dedicated-line number. High-mix shops that hit the schedule still print 45 to 70, and the gap is treated as a machine problem when the day was spent changing over.
A shop engagement is changeover treated as planned work, kit and program at the machine before the spindle stops, setup coded separately from downtime, and first-piece release against a schedule that does not borrow a dedicated-line OEE target. Full method: What we do.
20–30%
Share of a high-mix day that can go to setup.
Job-shop / high-mix capacity lost to setup; User Solutions and similar shop analyses.
44 min
Median changeover on tracked industrial machines.
Guidewheel Performance Analysis, 3,000+ machines: median changeover 44 minutes.
56%
Median changeover variability shift to shift.
Guidewheel Performance Analysis: median changeover variability 56.6%.
45–70%
OEE range common in high-mix plants that used to post 85 percent on long runs.
High-mix / job-shop OEE bands vs Nakajima’s 85% dedicated-line world-class mark.
Lot sizes dropped so the shop could take the order. The machine now changes over more than it runs.
Setup is planned work in a high-mix shop. When it is booked as downtime, the report and the floor stop agreeing.
World-class 85 percent is a dedicated-line number. High-mix shops that hit the schedule still print 45 to 70.
The spindle waits on a kit, a tool, or a program that is not at the machine.