Small losses build up across every shift. Microstops, slowdowns, waiting time. Most teams never see them.
Performance lossesThe line is running. Just not at full speed.
Small slowdowns that never get flagged, but reduce output over time
Microstops that last seconds, so no one logs them
Running below ideal speed without anyone noticing during the shift
Minor interruptions that seem harmless, but repeat all day
Individually, these are easy to ignore. Across a full shift, they add up to a meaningful loss in output.
Availability lossesThe machine could run. But something else gets in the way.
Waiting for maintenance while the line is ready
Waiting for parts, materials, or approvals
Changeovers taking longer than expected
Delays between teams that stop the process from starting
These delays are often seen as part of the job. Because of that, they are rarely challenged.
We now know the moment something goes wrong. The result? Problems don’t linger and past improvements aren’t lost.
This system is so visual, you can see the bar chart change as the day progresses. The CI team uses it daily for running reports, reviewing root cause analysis and looking at trends.
If you’re running blind, you’re always reacting. Data is what turns you from firefighting into leading. Maintmaster OEE is our daily driver. It powers a lot of our decisions.
